Back for round three: AM and chemistry returns to the spotlight

rapid.tech 3D is one of the few events to provide a platform for additive manufacturing (AM) in the chemical and chemical plant engineering industries. The topic will be on the agenda for the third year in a row, with the Chemistry & Process Engineering Forum taking place on 14 May. DECHEMA, Germany’s expert chemical engineering and biotechnology network, is also back on board as partner.

A topic that hits the mark

“The response to the two previous events shows that we have hit the mark. Those working in the chemical industry appreciate the creative insights and the chance to discuss the topic in depth with the AM community in Erfurt. We are pleased to have a competent partner in DECHEMA, which is once again supporting this year’s trade forum,” says Dr Özlem Weiss, Managing Director of Expertants GmbH. The PhD chemist pioneered the forum and, as a member of the rapid.tech 3D advisory board, is preparing the content for its upcoming third edition. “After providing an initial overview of additive manufacturing in chemical process engineering and then clustering the topics last year, a large part of this year's forum is dedicated to the development and commercial application of certified critical metallic AM components in chemical plants. We are also turning to a new area and presenting examples of how the pharmaceutical industry uses additive manufacturing. We will also be looking at new applications using ceramic and polymer materials,” summarises Dr Weiss.

AM components for high-performance heat exchangers in the hydrogen sector

Pump manufacturer KSB is a trailblazer in the production of certified, critical metal AM components. Stephan Braun, Business Development Manager Additive Manufacturing at KSB, and Ruben Steinhoff, Development Engineer at FUNKE Wärmeaustauscher Apparatebau, will give a joint talk on their project to develop a high-pressure heat exchanger for hydrogen refuelling stations, an important pressurised component for pre-cooling hydrogen. Additive manufacturing technology enables additional geometric freedom in the design of the heat exchanger, helping to keep construction compact and lightweight. The device’s scalable modular design means that it can be adapted to the installation space available. In addition, the presentation will highlight the challenges and solutions associated with complying with regulatory standards such as the Pressure Equipment Directive.

Similarly, Philipp Schwarz, Business Development Manager at Rosswag, will cover in his talk the advantages of additively manufactured heat exchangers in demanding applications such as process engineering, and examines the challenges of achieving Pressure Equipment Directive certification. He also reports on the company’s development of ultra-compact high-performance heat exchanger modules, a joint venture with Hülsenbusch Apparatebau, which manufactures systems for hydrogen production and utilisation.

AM gains popularity in the pharmaceutical industry

Additive manufacturing is establishing itself as a key technology in the pharmaceutical industry by enabling individualised and precise solutions for demanding production processes. In their joint presentation, Prof Dr Friedrich Bähr, owner of BaehrCon, and Raphael Schatton, Head of New Technologies & Innovation in the Manufacturing Science & Technology (MSAT) department at Sanofi-Aventis Germany, will discuss specific use cases such as the development of assembly fixtures for cleanrooms and high-precision systems for syringe handling in series production. In particular, they highlight the special challenges faced by the pharmaceutical industry, such as compliance with cleanroom classes, material requirements such as sterilisability, chemical resistance, abrasion resistance and regulatory certifications.

3D printing for ceramic membrane reactors

Managing partner of WZR ceramic solutions, Dr Dieter Nikolay, will present on the 3D printing of ceramics for membrane reactors, which can keep industrial processes operational in the absence of oil and natural gas. While current refineries still use the best available technology, membrane reactors would be able to produce basic materials such as ethylene or to generate synthesis gas from carbon dioxide and hydrogen. WZR plans to produce ceramic membranes and catalysts for these types of reactors; the 3D printing of functional ceramics plays a major role in this.

3D printing pioneer highlights challenges in AM transfer

Philipp Süß, founder and owner of the engineering firm Süß & friends, shares his thoughts on the challenges involved in AM transfer. Offering engineering services, practical knowledge and a collaborative approach, the expert group ensures that customers in the laboratory and chemical industries can rely on the successful application of additive manufacturing. Founded in 2017, the firm has already attracted attention at rapid.tech 3D. In 2021, Süß & friends won in the Digital category of the 3D Pioneers Challenge with its project “The Brush”, a brush for cleaning technical systems that is additively manufactured in just one production step.

Achieving precision at the atomic level

Danish company Atlant 3D is on a mission to take manufacturing technology to the next level and achieve atomic-scale precision in the production and assembly of advanced materials and components. In Erfurt, it is presenting the centrepiece of its DALP technology ‒ a proprietary microchemical reactor that it claims is revolutionising atomic layer deposition. Atlant 3D aims to build atomically precise manufacturing technology and infrastructure for micro- and nanoelectronics, optics and photonics on Earth and beyond.

Specialist conference offers a look at other current AM developments and applications

Alongside the Chemistry & Process Engineering trade forum, other forums at the rapid.tech 3D specialist conference provide insights into the latest AM developments and applications. On the first day, the VDMA AM4industry Forum, the Aerospace Forum and the quality-approved Science Forum invite visitors to delve into these topics. Day two of the programme includes the Electronics & Components and Mobility forums in addition to the Chemistry & Process Engineering Forum. The final day sees the forums Energy Technology & Hydrogen, Software, AI & Design and Innovation in AM welcome participants.

Presentations and a chance to chat to exhibitors, Deep Dive tours and Expert Tables

Visitors can also look forward to product and service demonstrations as well as small group discussions in Hall 2 – at the exhibitors’ stands or on guided Technical Deep Dive tours, at the Expert Tables, and at the AM Science Poster Slam in the hall.

The 3D Pioneers Challenge too is a source of inspiration, introducing completely new applications of additive and digital technologies. This year the international competition is back at rapid.tech 3D for the tenth time. The anniversary edition gives all previous finalists and winners the chance to go before the jury panel once again and scoop the title of “Pioneer of the Decade”.