@article{KesslerBalcGebhardtetal.2015, author = {Kessler, Julia and Balc, Nicolae and Gebhardt, Andreas and Abbas, Karim}, title = {Basic Research on Lattice Structures Focused on the Tensile Strength}, series = {Applied Mechanics and Materials}, volume = {Vol. 808}, journal = {Applied Mechanics and Materials}, publisher = {Trans Tech Publications}, address = {B{\"a}ch}, issn = {1662-7482}, doi = {10.4028/www.scientific.net/AMM.808.193}, pages = {193 -- 198}, year = {2015}, language = {en} } @inproceedings{KesslerBalcGebhardtetal.2017, author = {Kessler, Julia and Balc, Nicolae and Gebhardt, Andreas and Abbas, Karim}, title = {Basic research on lattice structures focused on the reliance of the cross sectional area and additional coatings}, series = {The 4th International Conference on Computing and Solutions in Manufacturing Engineering 2016 - CoSME'16}, booktitle = {The 4th International Conference on Computing and Solutions in Manufacturing Engineering 2016 - CoSME'16}, edition = {Vol. 94}, doi = {10.1051/matecconf/20179403008}, pages = {7 S.}, year = {2017}, language = {en} } @inproceedings{AbbasThurnKessleretal.2019, author = {Abbas, Karim and Thurn, Laura and Kessler, Julia and Eichler, Fabian}, title = {Basic research of the consideration of additive manufactured lattice structures under thermoand fluid dynamic loads}, series = {Modern technologies in manufacturing (MTeM 2019)}, volume = {299}, booktitle = {Modern technologies in manufacturing (MTeM 2019)}, number = {Article 01009}, doi = {10.1051/matecconf/201929901009}, pages = {8 Seiten}, year = {2019}, language = {en} } @article{WollbrinkMasloZimmeretal.2020, author = {Wollbrink, Moritz and Maslo, Semir and Zimmer, Daniel and Abbas, Karim and Arntz, Kristian and Bergs, Thomas}, title = {Clamping and substrate plate system for continuous additive build-up and post-processing of metal parts}, series = {Procedia CIRP}, volume = {93}, journal = {Procedia CIRP}, publisher = {Elsevier}, address = {Amsterdam}, issn = {2212-8271}, doi = {10.1016/j.procir.2020.04.015}, pages = {108 -- 113}, year = {2020}, abstract = {The manufacturing share of laser powder bed fusion (L-PBF) increases in industrial application, but still many process steps are manually operated. Additionally, it is not possible to achieve tight dimensional tolerances or low surfaces roughness. Hence, a process chain has to be set up to combine additive manufacturing (AM) with further machining technologies. To achieve a continuous workpiece flow as basis for further industrialization of L-PBF, the paper presents a novel substrate system and its application on L-PBF machines and post-processing. The substrate system consists of a zero-point clamping system and a matrix-like interface of contact pins to be substantially connected to the workpiece within the L-PBF process.}, language = {en} } @article{AbbasBalcBremenetal.2022, author = {Abbas, Karim and Balc, Nicolae and Bremen, Sebastian and Skupin, Marco}, title = {Crystallization and aging behavior of polyetheretherketone PEEK within rapid tooling and rubber molding}, series = {Journal of Manufacturing and Materials Processing}, volume = {6}, journal = {Journal of Manufacturing and Materials Processing}, number = {5}, publisher = {MDPI}, address = {Basel}, issn = {2504-4494}, doi = {10.3390/jmmp6050093}, pages = {1 -- 12}, year = {2022}, abstract = {In times of short product life cycles, additive manufacturing and rapid tooling are important methods to make tool development and manufacturing more efficient. High-performance polymers are the key to mold production for prototypes and small series. However, the high temperatures during vulcanization injection molding cause thermal aging and can impair service life. The extent to which the thermal stress over the entire process chain stresses the material and whether it leads to irreversible material aging is evaluated. To this end, a mold made of PEEK is fabricated using fused filament fabrication and examined for its potential application. The mold is heated to 200 ◦C, filled with rubber, and cured. A differential scanning calorimetry analysis of each process step illustrates the crystallization behavior and first indicates the material resistance. It shows distinct cold crystallization regions at a build chamber temperature of 90 ◦C. At an ambient temperature above Tg, crystallization of 30\% is achieved, and cold crystallization no longer occurs. Additional tensile tests show a decrease in tensile strength after ten days of thermal aging. The steady decrease in recrystallization temperature indicates degradation of the additives. However, the tensile tests reveal steady embrittlement of the material due to increasing crosslinking.}, language = {en} } @article{AbbasHedwigBalcetal.2023, author = {Abbas, Karim and Hedwig, Lukas and Balc, Nicolae and Bremen, Sebastian}, title = {Advanced FFF of PEEK: Infill strategies and material characteristics for rapid tooling}, series = {Polymers}, volume = {2023}, journal = {Polymers}, number = {15}, publisher = {MDPI}, address = {Basel}, doi = {10.3390/polym15214293}, pages = {Artikel 4293}, year = {2023}, abstract = {Traditional vulcanization mold manufacturing is complex, costly, and under pressure due to shorter product lifecycles and diverse variations. Additive manufacturing using Fused Filament Fabrication and high-performance polymers like PEEK offer a promising future in this industry. This study assesses the compressive strength of various infill structures (honeycomb, grid, triangle, cubic, and gyroid) when considering two distinct build directions (Z, XY) to enhance PEEK's economic and resource efficiency in rapid tooling. A comparison with PETG samples shows the behavior of the infill strategies. Additionally, a proof of concept illustrates the application of a PEEK mold in vulcanization. A peak compressive strength of 135.6 MPa was attained in specimens that were 100\% solid and subjected to thermal post-treatment. This corresponds to a 20\% strength improvement in the Z direction. In terms of time and mechanical properties, the anisotropic grid and isotropic cubic infill have emerged for use in rapid tooling. Furthermore, the study highlights that reducing the layer thickness from 0.15 mm to 0.1 mm can result in a 15\% strength increase. The study unveils the successful utilization of a room-temperature FFF-printed PEEK mold in vulcanization injection molding. The parameters and infill strategies identified in this research enable the resource-efficient FFF printing of PEEK without compromising its strength properties. Using PEEK in rapid tooling allows a cost reduction of up to 70\% in tool production.}, language = {en} }