TEAM UP - TEchnologies for sustainable Additive ManUfacturing and Post-processing
The TEAM UP project links Technische Universität Bergakademie Freiberg (Germany) and Indian Institute of Technology Palakkad (India) to push the frontiers of metal Additive Manufacturing (AM) and plasma electrolytic polishing (PeP) for next‑generation biomedical implants. Rising demand for patient‑specific CoCr implants highlight two AM bottlenecks: rough surfaces and dimensional drift, which conventional laser or mechanical finishing cannot solve, especially inside complex lattice geometries. PeP is an eco‑friendly, electrolyte‑based plasma process that simultaneously smooths and sizes parts, but its application to AM medical devices is largely unexplored.
Over 24 months, researchers will 3D‑print CoCr samples, apply optimized PeP regimes, and systematically quantify surface topography, mechanical integrity, and geometric fidelity. A novel design workflow and AI model will guide print and post‑process parameters for the lowest cost and highest quality. Joint experiments, staff exchanges, and student mobility strengthen labs and feed a textbook on sustainable PeP for implants. Equal‑opportunity policies promote gender balance and cultural diversity in all exchanges. TEAM UP lays the foundation for dual Master’s/PhD programs while accelerating safe, economical, and personalized implant manufacture.
Research Focus
- Metal additive manufacturing
- Post processing
- Plasma electrolytic polishing (PeP)
- Co-Cr implants
- Confocal Microscopic
- Material Characterization
Project duration
01.04.2025 – 31.03.2026 (extension sought until 31.03.2027
Projekt Partner
IIT Palakkad
Funding information
Funded by the German Academic Exchange Service (DAAD) with funds from the Federal Foreign Office (Auswärtiges Amt)
Main contact
Prof. Dr.-Ing. Henning Zeidler
+49 3731 39 3066
additive_fertigung [at] imkf [dot] tu-freiberg [dot] de (additive_fertigung[at]imkf[dot]tu-freiberg[dot]de)
Research Team
TUBAF-Team:
Dr. Deeksha Lohani
Dipl.-Geol. Manuela Junghans
Dr.- Ing. Rezo Aliyev
Dipl.-Ing. Martin Krinke
Dr. Neel Kamal Gupta
IIT Palakkad-Team:
Dr. Afzaal Ahmed
Dr. Jibin Boban
M.Tech. Sahid Illikkal
Work Package 1: AM-Part Design and Fabrication
Design and fabricate biomedical-grade CoCr parts using Laser Powder Bed Fusion (PBF-LB/M) at varying orientations and textures. Apply optimized build strategies to produce samples for surface and dimensional studies.
Work Package 2: PeP Post-Processing and Characterization
Conduct plasma electrolytic polishing on AM parts. Perform in-depth surface and mechanical characterization using SEM, XRD, optical profilometry, hardness, tensile testing, and CMM to assess PeP performance.
Work Package 3: Design Framework and AI Integration
Develop a parametric design framework and AI-based model to optimize part quality, cost, and surface finish post-PEP. Study the relationship between AM parameters, PeP outcomes, and geometric fidelity.
Work Package 4: Knowledge Exchange and Dissemination
Enable student and faculty exchange between TUBAF and IIT Palakkad. Host joint workshops, publish a comprehensive textbook on eco-friendly PeP, and submit peer-reviewed research and conference papers.
