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Additive manufacturing (AM) opens up new avenues for mechanical and plant engineering in component design, functional integration, and resource-efficient production. At Fraunhofer IWS, robust, industry-ready solutions are being developed with a focus on wire- and powder-based laser metal deposition (LMD-wire and LMD-powder) as well as powder bed processes. These processes enable both cost-effective new production and targeted repair and functionalization of complex components.

A current example is the project for the additive manufacturing of impellers for various branches of industry. By combining simulation, material selection, and process-optimized manufacturing, mechanically resilient, flow-optimized geometries can be achieved—while simultaneously saving material and allowing for design freedom.

As part of the UltraGrain project, the IWS is researching the targeted use of laser wire deposition welding to adjust defined microstructures using so-called “grain engineering” approaches. By controlling temperature gradients and solidification conditions, tailor-made microstructures can be created – a decisive lever for improved properties such as strength, toughness, or corrosion behavior.

In addition, the IWS is developing processes for the additive repair of heavily stressed components, for example through sensor-supported reconditioning of worn surfaces or geometrically complex components. Integrated process monitoring and control systems are used to ensure reproducible quality and enable industrial implementation.

The presentation shows how additive manufacturing technologies are being brought to market maturity at the IWS in collaboration with industry partners—also as part of hybrid manufacturing solutions—for greater sustainability, flexibility, and economic efficiency in mechanical engineering.


Fraunhofer IWS


Fraunhofer IWS


Dr. Elena Lopez

Dr. Elena Lopez

Dr. Elena Lopez studied chemical engineering at the Universidad de Valladolid and Friedrich-Alexander-Universität Erlangen-Nürnberg. She finished her PhD thesis about the topic of plasmachemical etching of silicon solar wafers at the Technische Universitaet Dresden. She is Head of Department for Additive Manufacturing at the Additive Manufacturing Center Dresden (AMCD) at Fraunhofer IWS and teaches AM as adjunct professor. She also represents Women in 3D Printing as Regional Director Europe.