FOTEC advances automated post-processing in metal AM with Hirtisation technology and process chain optimisation
May 20, 2025
Forschungs-und Technologietransfer GmbH (FOTEC), a research subsidiary of the University of Applied Sciences Wiener Neustadt, Austria, has developed key technologies for the integration of Additive Manufacturing into industrial process chains as part of the international joint project Ad-Proc-Add II. The focus was on automated post-processing using Hirtisation, the characterisation of additively manufactured surfaces, and the development of database systems for process optimisation.
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The project, funded by the Austrian Research Promotion Agency (FFG), the German Federal Ministry for Economic Affairs and Climate Action (BMWK), and the Flanders Agency for Innovation & Entrepreneurship (VLAIO), was coordinated by the ecoplus Mechatronics Cluster, FKM, and KU Leuven. Its aim was to make Additive-Subtractive Manufacturing (ASM) chains economically viable – including for small and medium-sized enterprises (SMEs).
In this context, FOTEC acted as a leading player in the field of Laser Beam Powder Bed Fusion (PBF-LB) as well as electrochemical and mechanical post-processing.
Hirtisation: rethinking chemical-electrolytic post-processing
A highlight of FOTEC’s contribution was the further development of the Hirtisation technology – an electrochemically assisted post-processing method for support removal, cleaning, and smoothing of PBF-LB components. Building on the results of the preceding project, targeted processing strategies were developed for materials such as Ti6Al4V and 1.4404 stainless steel.
By adapting PBF-LB process parameters, machining allowances as low as 180-550 μm could be defined – an important step toward material-efficient, automated post-processing. At the same time, surface roughness values of Sa ≤ 5 μm were achieved, enabling the precise functionalisation of AM components.
Targeted control of surface quality
As part of the project, FOTEC conducted extensive investigations into the surface integrity of additively manufactured parts. The research focused on analysing how various PBF process parameters, build orientations, and intermediate treatments influence the final surface properties.
Special attention was given to the interaction with processes such as shot peening, heat treatment, and CNC profile grinding. The resulting surface matrix provides a solid foundation for the targeted combination and optimisation of Additive and Subtractive process steps.
Data management in hybrid process chains
A major contribution to digital continuity was the development of a cross-process data management system, implemented in the current project by the Institute of Production Engineering and Photonic Technologies at TU Wien in collaboration with project partners. In a prototype setup, a hybrid CAM system was supplied with multi-sensor real-time data, from which tool paths were automatically generated.
By integrating sensor data, material properties, and geometry information, an intelligent, adaptive CAM control system was created, marking a milestone in the automation of complex Additive-Subtractive Manufacturing process chains.
Application-oriented and transfer-focused
FOTEC’s research efforts were characterised by a strong application focus. Throughout the project, test specimens and use cases were produced and analysed using materials such as Ti64, 316L, and AlSi10Mg. Close collaboration with the 15 industrial partners, including companies from the aerospace, tooling, and medical technology sectors, ensured that the developed processes could be directly transferred to real-world manufacturing scenarios.
