Strain gauges are used to measure the deformation of parts under load. For highly specified parts, the deformation values determined using the strain gauges can be used to measure the force acting on the part. In this context, deformation plates in conjunction with the strain gauges form a sensor.

With the PBF-LB/M process, components such as deformation plates can be inserted into the manufactured parts during the process. The process can then be restarted and the inserted components are fused with the subsequent layers and the components.

In order to create a sensor that can be integrated into complex structures, prototypes were built in which deformation plates were inserted during the printing process. The plates were successfully fused with the additively manufactured parts and the sensors were found to be functional. Tests showed reliable force transmission and sufficiently low deformation hysteresis. This implementation of the sensor concept lays the foundation for deeper sensor integration into the force flow of additively manufactured parts.