As part of the FlaMe research project, a new machine for laser powder bed fusion of metallic materials (PBF-LB/M) with a high-power green laser from Fa. Trumpf was successfully installed. The machine will be used within the project to overcome the challenges of laser-based processing of high-purity copper materials and thus enable novel assembly concepts of power electronic modules.

The Flame research project aims to develop a flexible and energy-efficient process chain for the production of customer-specific power electronics in small batches. Depending on the area of application and the function to be fulfilled, the products vary in their structure, the materials used and the semiconductor components. The resulting product diversity poses a challenge for the current process chain of power electronic modules. To solve this problem, a manufacturing concept is being developed which, by substituting conventional processes, enables a reduction in process complexity and the required resources while simultaneously increasing flexibility. Thanks to its digital process control, laser powder bed fusion allows the production of individual, geometrically complex components without the use of product-specific tools. However, the process-safe processing of copper with infrared radiation of established laser systems is a challenge due to the high reflection behavior. By increasing the absorption of copper in the green spectral range, the high energy required to melt the powder material can be efficiently introduced. In order to further benefit the process and also to be able to manufacture novel products such as additive metallized ceramic substrates, the build platform is additionally equipped with a resistive high-temperature heater designed for 800 °C.

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