The FlexMat3D project is developing a universal extruder interface for a large-format 3D printer and an adaptable printing process for multi-material applications. The first step is to define the technical requirements and demonstrators, including the selection of materials and specific use cases. Based on this, the methodical design and construction of a flexible extruder for the 3D printer and an extruder change system for the efficient adaptation to different materials will be carried out. In the next step, the partial solutions will be installed in the printer, tested, and optimized. At the same time, a targeted process development will begin to optimize the printing parameters and path planning for simultaneous mono-material printing using two print heads. Building on this, a multi-material printing process will be developed and the process management, printing strategy, and connection zones between different materials will be optimized. Finally, test geometries and realistic multi-material demonstrators will be manufactured and characterized in order to determine process limits and validate the functionality of the technology.

Duration: 01.02.2026 - 31.01.2028

Responsible employee: Jan Hünting

Funding programme: This project is funded by the Federal Ministry for Economic Affairs and Energy (BMWE) based on a resolution passed by the German Federal Parliament. FKZ: KK5261807.

Project manager: Allianz für Industrie und Forschung - AIF e.V.

Project partner: Teccon Consulting & Engineering GmbH