Showcase #1: Lattice Structures.

Additive manufacturing enables material to be placed exactly where it delivers value. Periodic lattice structures unlock new design possibilities—ranging from lightweight components and energy-absorbing zones to functional separation layers within a single part.

This demonstrator showcases three representative lattice architectures: Gyroid, Octet Truss, and Schwarz-P. Each structure follows a distinct geometric principle and offers specific performance characteristics in terms of stiffness, load distribution, damping, and functional integration.

By selecting and tailoring the appropriate lattice architecture, component performance can be precisely adapted to application requirements—whether structural efficiency, energy absorption, or thermal and mechanical decoupling.

Showcase #2: Lightweight E-Motor Housing with Integrated Air Cooling

This part illustrates the development of a highly integrated, additively manufactured motor housing for a Formula Student race car, carried out in collaboration with the CTM Formula Student Team and MonaLab GmbH.

The design targets a high-performance electric motor with a peak power of 35 kW and a peak torque of 30 Nm. Under demanding operating conditions, efficient thermal management becomes critical. To address this, the housing incorporates fully integrated air-cooling features directly into the component geometry.

Produced in AlSi10Mg on an SLM platform, the housing achieves a weight of approximately 580 g. The cooling concept is based on an array of thin fins with wall thicknesses down to 0.50 mm, maximizing surface area for heat dissipation while maintaining structural performance.

Such geometries highlight the importance of advanced scan strategies and precise process control, particularly in regions with extreme aspect ratios. Approaches based on highly localized energy input, for example single-track exposure strategies, can enable the reliable fabrication of these fine structures while also offering potential for build time optimization.

This showcase demonstrates how additive manufacturing expands the design space for functional integration, combining lightweight construction, thermal performance, and process-driven innovation within a single component.

To make the most of AM, several key considerations are essential. First, Design for AM (DfAM) involves topology optimization and lightweight structures to maximize efficiency and functionality. Second, material selection is crucial: choosing the right materials enhances the strength, durability, and sustainability of the final product. Finally, iterative prototyping enables rapid testing, and refining of designs, ensuring the best possible outcomes.

In our view, the future of manufacturing lies in combining all available methods, enhanced by the comprehensive AM toolbox.

Manufacturing network.

With our strong partner network, we offer a wide variety of machines and tools for rapid prototyping, post-processing, and CNC machining.

Showcase #3: Working with powder prototypes.

At MATERIA, working with specialized additive manufacturing powder prototypes allows components to be optimized for their specific application. By combining the right material with tailored process parameters, powder prototypes can achieve enhanced mechanical performance, thermal behavior, or functional integration compared to conventional approaches.

The microstructure of the powder itself plays a crucial role in unlocking the full potential of additive manufacturing. Our integrated approach to material and process development ensures reproducible quality and enables prototypes and series parts to fully benefit from the capabilities of both material and AM technology.

Showcase #4: Process Development in LPBF

Process development in LPBF goes beyond identifying stable build parameters, it is a structured approach to tailoring material behavior through process control.

Key parameters such as laser power (P), scan speed (v), beam diameter (σ), hatch spacing, and layer thickness (t) define the energy input, commonly expressed as VED=P/(vσt).​

While volumetric energy density is often used as a baseline indicator (e.g., achieving ~98 – 100% relative density), it also directly influences microstructure formation. In practice, the laser acts less as a simple heat source and more as a tool for microstructural control, affecting properties such as strength and ductility.

By systematically evaluating test specimens, process windows can be identified that balance part quality and productivity. At the same time, for example, porosity can be intentionally engineered — not as a defect, but as a functional feature. Through scan strategy and parameter selection, defined pore structures can be created for applications such as thermal insulation, fluid absorption, or filtration.

Process development therefore defines a broader design space where both geometry and material properties are engineered through the laser process itself.