Joint Forces on Additive Manufacturing of Premium Parts Designed for Extreme Thermal Strains

The Research Center JOANNEUM RESEARCH, the University of Applied Sciences FH JOANNEUM and the Engineering Office specialised in advanced combustion management COMBUSTION BAY ONE join their forces and design the better burner together. CBOne is in charge of the design, FHJ is in charge of the modelling, and JR is in charge of the commissioning using additive manufacturing of metals (PBF / Powder Bed Fusion). To seal this commitment about better burners produced with additive manufacturing (AM), the three parties have signed in October 2017 a common letter of intent.


Picture of the first fire at the CBOne labs using self-designed AM parts

CBOne and JR take part in a pilot study on Additive Manufacturing using Inconel 718 (FFG contract 862837). A common publication with the participation of FHJ is planned 2018.  The figure shown is the first result of this study - shortly said it works and it works well. 

Click “read more” to see the full text of the letter of intent.


Figure: from mathematics to the innovative swirler shape.

Abstract from the works by Paulitsch et al. (in German), presented at the Symposium EnInnov 2018


Letter of intent:

Defining the Rules of Best Use of Additive Manufacturing,

by the consortium composed of Combustion Bay One e.U., FH JOANNEUM Gesellschaft mbH 

and Joanneum Research Forschungsgesellschaft mbH



3D-printing of metals is a new manufacturing technique with a great potential, in terms of development as in terms of deployment.

In theory, it is possible to produce rapidly complex parts - where the design is free of the constraints inherent to the usual production methods (milling, drilling, turning and casting). In theory, the designer can concentrate on the functionality of the part and optimise features such as weight, volume, structural and dynamic mechanics, and global integration. In theory, one part can replace many that used to be assembled. In theory, it is easier to integrate new features such as advanced thermal management or instrumentation ports using additive manufacturing.

In practice at currents state-of-the-art, the production costs are high. The maximal size of these parts is limited. The production rate is low. The surface' roughness of the parts can be a problem. The structural and dynamic properties are production-dependant and are not yet well described. Temporary building structures are sometimes needed and have to be removed in post-process, therefore these have to be accessible.

The consortium Combustion Bay One (CBOne), FH JOANNEUM – Institute of Aviation (FHJ) and Joanneum Research - Materials (JR) declare their intention to join forces.

• The incentive is to make the best possible use of additive manufacturing by sharing their capacities and know-how: design for CBOne, testing for FHJ and methods for JR.

• The starting point is the design of a low-emission gas burner.

• The aim is to concentrate on premium parts, where the functional complexity is high and where the typical production rate is of the order of 1000 parts per facility per year.

• The goal is to establish the conditions under which additive manufacturing concurrences and even beats conventional manufacturing techniques.

• The hope is a return to regional production, the modern forge of the modern village.

In the years to come, the consortium will gain in best-practice, and make progress on all the aspects cited before. An input of importance is education, provided by FHJ, and the dissemination by all three. Of course, the industry is invited to interact as soon as possible and submit challenging test cases.


Combustion Bay One e.U.

FH Joanneum Gesellschaft mbH

Joanneum Research Forschungsgesellschaft mbH