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Research Unit 5620: Simulation-based design and production of load-optimised freeform components by laser metal deposition (DED-LB/M)

Funded by the German Research Foundation (DFG) – 512940050



The aim of the research group is to gain a comprehensive understanding of the design and production of load-optimized free-form components. Robot-based laser deposition welding (DED-LB/M) with wire-shaped filler material is to be investigated as a manufacturing process, taking into account the residual process stresses and subsequent machining processes. The production of topology-optimized components, which require only a fraction of the weight of conventional components, is a central basic idea, which not least serves to conserve resources in production. Topology optimization delivers load-optimized complex structures that can no longer be produced using conventional manufacturing processes, or only with considerable effort.

News

CIRP Winter Meetings

At the CIRP Winter Meeting in Paris from February 18 to 20, 2026, Petra Wiederkehr, head of Subproject 7, presented the research group’s latest work. The joint presentation with Melina Wenzel focused on discussing the potential and challenges of modeling robot-assisted milling of additively manufactured components. CIRP is the International Academy for Production Engineering and ranks among the most renowned scientific networks in this field.

University Council and Rectorate of Ruhr University Bochum at ZESS: Current work of Research Group 5620 presented

On February 13, 2026, the University Council and Rectorate of Ruhr University Bochum met at the ZESS research building. One of the items on the agenda of the two central committees was a tour of the research building, conducted by ZESS Director and FOR 5620 subproject leader Prof. Dr.-Ing. Bernd Kuhlenkötter.
During this tour, Dominique Piorreck and Jan Schachtsiek presented the robot cell that is at center of FOR 5620 and the latest research results. The presentation met with great interest and led to an intensive exchange on development prospects and further potential of the research work.

WAXS experiments at the DELTA synchrotron source for microstructural analysis of additively manufactured materials

In Subproject 6 of the Chair of New Manufacturing Technologies and Materials, WAXS experiments were carried out at the DELTA synchrotron radiation source at TU Dortmund University. The aim of the investigations was to experimentally analyze the microstructure as a function of local build height in DED-LB/M-manufactured samples and associated thermal effects, in order to draw conclusions about microstructure evolution in subsequent topology-optimized, complex DED-LB/M components.

Research findings presented at IEEM 2025 in Melbourne

At the IEEE International Conference on Industrial Engineering and Engineering Management 2025 (IEEM 2025), which took place from December 7 to 10, 2025, in Melbourne, Australia, Jan Schachtsiek from the Chair of Production Systems presented current research results as part of the DFG Research Group 5620. In his presentation entitled “Influence of Laser Power in Wire DED-LB/M on Machinability in Robotic Hybrid Manufacturing,” which was developed in collaboration with project partner LAT, he presented new findings on the process design of hybrid manufacturing systems.

Publication: DOI 10.1109/IEEM63636.2025.11357850

First half-year meeting on November 6 and 7, 2025

All project managers and doctoral students met at the ZESS – Center for Engineering Smarter Product-Service Systems in Bochum for the first half-year meeting. The latest progress was presented and discussed over two days.

MSE2026: Simulation-Based-Design and Additive Manufacturing of Load-Optimized Components

We’re excited to host the symposium "P04: Simulation-Based Design and Additive Manufacturing of Load-Optimized Components" at MSE 2026 — one of Europe’s major materials events, 29 Sep – 01 Oct 2026 in Darmstadt and online. Submit your abstract to discuss and connect with the community.