As part of the international research project Ad-Proc-Add II (Advanced Processing of Additively Manufactured Parts II), the Institute of Production Engineering and Photonic Technologies (IFT) at TU Wien is making a vital contribution to the advancement of hybrid manufacturing processes.
In close collaboration with partner institutions from Austria, Germany, and Belgium, IFT has developed innovative approaches for combining additive and subtractive methods along the entire process chain.
The Institute of Production Engineering and Photonic Technologies (IFT) at the Vienna University of Technology (TU Wien) is one of Europe’s leading research institutions in the field of manufacturing science. With a focus on additive manufacturing (AM), precision machining, and digital process integration, IFT aims to develop innovative solutions for the production of the future.
The project—funded by the Austrian Research Promotion Agency (FFG), the German Federal Ministry for Economic Affairs and Climate Action (BMWK), and the Flanders Agency for Innovation & Entrepreneurship (VLAIO)—was coordinated by the ecoplus Mechatronics Cluster, FKM, and KU Leuven. Its goal was to enhance the cost-efficiency and precision of manufacturing highly complex components. In this context, IFT played a key role in developing innovative, application-ready technological solutions using simulation-based process models, which are expected to make future industrial applications significantly more efficient and sustainable.
Materials and Process Knowledge for WAAM Components
One of IFT’s research priorities was the analysis of the resulting material structure and surface integrity along the Additive-Subtractive Manufacturing (ASM) process chain. In the area of Wire Arc Additive Manufacturing (WAAM), researchers in Vienna examined, among other factors, the influence of various process parameters and post-processing methods on surface and substructure properties. The findings provide crucial insights for the targeted adjustment of component characteristics such as hardness, residual stresses, and surface roughness.
Machine Hammer Peening, an intermediate treatment method tested by IFT, demonstrated significant improvements in the densification and homogenization of the surfaces of additively manufactured components. When combined with methods such as shot peening and Hirtisation, post-processing could be systematically optimized.
Simulation as a Bridge Between Additive and Subtractive Manufacturing
A key contribution from IFT was the development of a simulation model to predict the topography, stress distribution, and deformation of additively manufactured components even before the actual production process begins. Using the Finite Element Method (FEM), a foundation was established for predictive process planning.
In a further step, the simulation was extended to include an analysis of machinability—with the goal of optimizing machining strategies in advance based on the AM data. This enables precise definition of the minimum necessary machining allowances, significantly reducing material consumption and post-processing time.
Hybrid CAM Systems and Process Data Databases
To support the digital integration of the ASM process chain, IFT also developed a prototype of a CAM rule engine. This enables the automated adjustment of toolpaths based on sensor-driven process data. The system was embedded into a custom-developed cross-process database that links parameters and sensor data from various stages of manufacturing. This brings the vision of a fully data-driven process chain within reach.
Key Role for Small and Medium-Sized Enterprises (SMEs)
IFT placed particular emphasis on industrial applicability—especially for small and medium-sized enterprises (SMEs). By strategically combining research, simulation, and practical validation, usable solutions were developed in collaboration with 15 Austrian industry partners, including approaches for the seamless integration of WAAM processes into existing production lines. The result: technologies that are practical, cost-effective, and scalable.
Strong International Collaboration
The Ad-Proc-Add II project was coordinated by the Research Association for Mechanical Engineering e.V. (FKM) and supported by renowned institutions such as the Institute for Machine Tools (IfW) at the University of Stuttgart and the Institute for Machining Technology (ISF) at TU Dortmund University. IFT, with its interdisciplinary team led by Univ.-Prof. Dipl.-Ing. Dr.techn. habil. Friedrich Bleicher, played a central role in the project.
The research findings are being shared through professional events, trade fairs, and publications—including at EMO 2025 in Hanover and in leading international journals.
www.ad-proc-add.eu
