Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI
Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMI
© Fraunhofer EMI

Functionally graded microstructure achieved through targeted process parameter variation: EBSD reveals controlled grain size gradients and corresponding property transitions.

© Fraunhofer EMI

3D-Printed Metals for High-Speed Dynamics

Tailoring additive materials for extreme loading conditions

At Fraunhofer EMI’s Additive Design & Manufacturing group, we specialize in the additive manufacturing of high-performance metallic materials for high-strain-rate environments such as ballistic impact, blast loading, and other types high-speed mechanical loading.

We support industrial and research partners in processing advanced alloys for extreme loading conditions by means of targeted process parameter development, enabling tailored material properties using advanced additive manufacturing technologies.

Our material competencies include:

  • High-performance steels: armor, high-strength, tough
  • Processing of heavy metals: tungsten, tantalum, copper
  • Metal-matrix composites: W-Fe, W-Ta
  • Microstructural gradients
  • Adapting mechanical properties

Our work focuses on steels engineered for strength, toughness, and ductility, as well as heavy metals like tungsten, tantalum, and copper – processed through Laser Powder Bed Fusion (PBF-LB/M). Through systematic variation of process parameters, we achieve functionally graded microstructures (FGM) with locally tailored properties such as hardness or strength or simply to adapt their mechanical properties. This enables components to exhibit properties that match the specific mechanical demands of their application. 

© Fraunhofer EMI
Additive manufacturing of heavy metals such as tungsten, tantalum, and copper via PBF-LB/M – enabling robust solutions for extreme environments by tailoring mechanical properties and addressing material-specific challenges such as micro-cracking.

In addition, we develop metal matrix composites (MMCs) combining refractory and ductile constituents to engineer novel material combinations and extend the design space beyond conventional alloys. These tailored materials are designed for applications such as energy-absorbing structures, armor components, novel military solutions, or dynamically loaded lightweight elements – wherever conventional alloys reach their limits.

© Fraunhofer EMI
Ashby diagram: Our steels and optimized processing strategies enable a wide range of strength–ductility combinations.

Materials are produced in-house using both industrial and research-grade PBF machines, ensuring full process control and and protection of restricted information (conformity to equivalent of EU-RESTRICTED). Microstructural and mechanical characterization is performed using advanced methods including EBSD, EDX, and testing under both dynamic and quasi-static conditions – enabling reliable performance assessment across strain-rate regimes.

Our capabilities span the full development chain: from material design and simulation to processing and mechanical validation. Partner with us to benefit from our expertise in advanced materials and additive manufacturing. We look forward to shaping the next generation of high-performance materials with you.

© Fraunhofer EMI
Functionally graded materials: tailored process strategies enable property gradients. Example: linear increase in hardness from bottom to top.
© Fraunhofer EMI
Additive manufacturing enables new metal matrix composites (MMCs), combining distinct materials to enhance mechanical performance and unlock novel property profiles.