Daniel Mayer

Dr. Daniel Mayer


Research Focus & Metrics

Academic Career Length

4Years (2023-Present)

(Calculated once Scilit publication data is synced: current year − year of first publication + 1)

Representative Publications

View All Publications
13 October 2023 in Materials
Verified
Journal Article
Open access
PDF file
PSPhilipp Schüßler
Philipp Schüßler
JFJonas Franke
Jonas Franke
SCSteffen Czink
Steffen Czink
SASteffen Antusch
Steffen Antusch
DMDaniel Mayer
Daniel Mayer
SDStefan Dietrich
Stefan Dietrich
This work presents a comprehensive investigation into the optimization of critical process parameters associated with metal fused filament fabrication (Metal-FFF) for the production of copper-based components. The study focused on three different commercial and one self-manufactured filament, each with unique chemical compositions. These filaments were systematically optimized and the density was characterized for all processing steps, as well as the electrical conductivity on the specimen scale. Remarkably, two of the studied filaments exhibited exceptional properties after sintering with forming gas (up to 94% density and 55.75 MS/m electrical conductivity), approaching the properties measured for established manufacturing methods like metal injection molding. Finally, the research was extended to component-scale applications, demonstrating the successful fabrication of inductors with integrated cooling channels. These components exhibited water tightness and were used in induction hardening experiments, validating the practical utility of the optimized Metal-FFF process. In summary, the results show great promise in advancing the utilization of Metal-FFF in industrial contexts, particularly in the production of high-performance copper components.