Integration of components in 3D-Printing Process

Integration of components in 3D-Printing Process

Function integration by inserting arbitrary components during additive manufacturing

Intellectual Property and Innovation Management

Deniz Bayramoglu, +49 6151 16-57215

Robert Heitzmann, +49 6151 16-57228

Status quo

The enclosure of components during the additive manufacturing process by laser beam melting of metal powder is only possible by interrupting the manufacturing process. The powder is removed, the component is inserted and then a flat layer of powder is applied before the manufacturing process is continued.

Our technology: AM-Process for enclosing components with arbitrary geometry

Due to the arrangement of re-coater and rotating construction platform, the powder can also be placed directly on arbitrary shaped, inserted components. The laser can melt the powder and enclose the component with material.


  • Integration of sensors of arbitrary geometry into additively manufactured components.
  • Integration of semi-finished products into the additive manufactured components.
  • No interruption of the construction process necessary to insert the components.

Current stage of development

Technology-Readiness-Level (TRL): Level 2.

The concept of the insertion process has been drawn up and a prototype is in development.

Application possibilities

The possibility of enclosing components allows additional functions to be integrated into products. Furthermore, the properties of the components can be specifically influenced by inserting semi-finished products.

Commercialization opportunities

For the implementation of the technology, we are looking for interested companies who would like to extend their product portfolio or open up new business fields. There are various possibilities for cooperation between the industrial partner and TU Darmstadt: from an exchange with the know-how carriers of the technology up to a close cooperation in case of further development needs. The technology is protected by intellectual property rights and can be used by the industry partner after a sale or licensing agreement.