Topology Optimization Meets Wire-Based Additive Manufacturing: Completed TopoDED Project Establishes New Foundations for Resource-Efficient Hybrid Components

Topology-optimized components combine high mechanical performance with low material usage. However, their complex geometries pose particular challenges for design and manufacturing. In the “TopoDED” project, topology optimization and wire-based laser metal deposition (Directed Energy Deposition, DED-LB-M/w) were therefore brought together in a joint development approach.

A simulation-supported workflow coordinates component optimization, material distribution, path planning, and process control. The software framework developed also enables the mapping of hybrid components with defined transition zones.

Neue Materialien Bayreuth GmbH further developed the DED-LB-M/w process for topology-optimized and hybrid components. An independently controllable dual-wire feed enables the targeted use of different wire materials and diameters as well as in-situ alloying. In addition, path guidance and hatching strategies for stable material deposition were investigated. A hybrid impeller was produced as a demonstrator, featuring an inner section made of an Fe-X alloy and blades made of Ti6Al4V.

The findings gained can be transferred to industrial applications in the future, for example to lightweight structures for aviation, impellers and turbine components for energy technology, as well as highly stressed components in mechanical and automotive engineering.

The “TopoDED” project was jointly carried out by Gravis Engineering GmbH and Neue Materialien Bayreuth GmbH. It was funded by the Federal Ministry for Economic Affairs and Energy (BMWE) as part of the Central Innovation Programme for SMEs (ZIM) (funding reference KK5027511WO3).