Fraunhofer IWU introduces Epic3D LFAM system

Researchers at Fraunhofer IWU‘s new SEAM Research Center are exploring the possibilities of Screw Extrusion Additive Manufacturing (SEAM). The center’s main feature is Epic3D, a newly developed portal printer that can produce large plastic components. By continuously depositing material and incorporating stiffening structures, it creates durable parts. This makes the technology ideal for producing custom-designed facade elements and other weather-resistant products for the construction industry.

For complex designs like facade elements with different textures or custom shapes like a company logo, 3D printing shows its full advantages. Until now, AM has been limited by the size of the build platform and by slow, expensive processes that use filament instead of granules. In collaboration with Wirth & Co. GmbH, Fraunhofer IWU focuses on large-format components for the building sector, such as customizable facades. Similarly, the SEAM process is a good choice for producing fences or gates because it offers high quality, cost efficiency, and fast production times. The partners emphasize that their plastics will meet all fire safety requirements and UV and weather resistance standards.

The SEAM printing process works by drawing in and melting granules through a modified extrusion screw. The melted plastic is then deposited layer by layer onto the build platform. This tool-free manufacturing process makes custom designs affordable. High printing speeds also help reduce costs.

“We make sophisticated design affordable. The personal touch in facade design is, of course, also achievable in traditional manufacturing. But only with processes like SEAM is it cost-effective,” said Dr. Martin Kausch, head of the Department of Sustainable Fiber-Plastic Composites at Fraunhofer IWU.

“With 3D printing in the SEAM process, completely new design possibilities are opening up in facade construction. Together with Fraunhofer IWU, we are optimizing design, materials, and the 3D printing process for applications in the construction industry. With our investment in the Epic3D portal system, we are making additive manufacturing fit for building components,” said Florian Stöckel, Managing Director of Wirth & Co. GmbH.

At the SEAM Research Center, Fraunhofer IWU has developed three systems in collaboration with Metrom and 1A Technologies UG. The Epic3D stands out with its 2-meter-long and 1.7-meter-wide build platform. The METROM P1410 allows for additional processing steps like milling. The third system, the SEAMHex, uses a hexapod – a swiveling 6-axis parallel kinematics system – that gives the build platform exceptional movement flexibility. This movement system features high dynamics and low moving masses, resulting in high positioning and path accuracy.