toolcraft and Siemens bring porous structures to industry with AM

Innovation in additive manufacturing continues to push boundaries, and toolcraft, in collaboration with Siemens, is leading the way in bringing porous structures to industrial applications. For many years, these two industry leaders have been leveraging the potential of additive manufacturing technologies, and their latest focus on porous metallic structures represents a significant leap forward for various industries.

Toolcraft and Siemens: partners in industrial manufacturing

Siemens, a global leader in industrial technology, has long been engaged in developing highly optimized porous material structures through additive manufacturing. This collaborative partnership with toolcraft, a specialist in additive manufacturing and precision manufacturing, has resulted in innovations across a wide spectrum of industries.

Porous metallic structures, similar to how a sugar cube absorbs liquid through its capillary action, can transport liquids or manage heat more efficiently. This characteristic opens doors to innovative designs in aerospace, energy processes, mechanical engineering, and chemical reactions. Siemens has successfully integrated these materials into components to provide advanced heat transport and cooling capabilities, significantly enhancing their performance.

One of the most notable achievements is the creation of functionally optimized porous structures through Siemens’ research. In collaboration with toolcraft, these developments have moved from research into real-world applications, enabling innovative and efficient solutions for industries that require advanced material performance.

From 3D-PROCESS Project to industrialization

The partnership between Siemens and toolcraft is built on a long-standing relationship and a shared vision for the future of manufacturing. This collaboration has been supported by the 3D-PROCESS project, funded by the Federal Ministry of Economics and Technology, which was focused on creating the first demonstrators for chemical reaction technologies using porous materials. The project underscored the vast potential of porous structures, and Siemens saw the opportunity to extend their use to other high-performance sectors.

“Porous structures have shown enormous potential across various industries,” said Dr. Karsten Heuser, Vice President Additive Manufacturing at Siemens Digital Industries. “We see applications in aerospace, energy process engineering, and beyond. With toolcraft, we are now building the strategic bridge for industrial production of these complex structures.”

Siemens and toolcraft aim to develop these porous components according to stringent industry standards. Christoph Hauck, Chief Technology and Sales Officer at toolcraft AG, added, “We are working to ensure that porous structures meet the needs of all industry applications, particularly in energy process engineering. With this partnership, we will ensure compliance with all relevant industry standards, including the European Pressure Equipment Directive 2014/68/EU for materials such as Hastelloy® C22, which we’ve been using for more than a year.”

Advantages of porous structures

Additive manufacturing has made significant strides in recent years, but the development of porous structures is one of the most exciting innovations to emerge. These structures offer a unique combination of permeability and structural stability, enabling highly functional designs that are difficult to achieve using conventional methods.

Toolcraft and Siemens are focusing on powder bed fusion processes (L-PBF), which allow precise control over pore size and distribution in metallic parts. This capability optimizes the structural and functional requirements of components, especially in applications where pressure management, heat dissipation, or liquid absorption is critical. For example, in energy process engineering, porous components can equalize excess pressure, maintain thermal stability, and absorb liquids effectively. These properties make porous structures indispensable in process industries, where components are subjected to extreme operational conditions.

“Porous metallic structures can revolutionize industrial manufacturing,” explained Christoph Hauck. “From reducing component weight to improving temperature control, the benefits are clear. Our goal is to take this technology to all plants and systems, ensuring that it is fully applicable across the industrial spectrum.”

Targeting full-scale industrial applications

The potential for porous structures in additive manufacturing is enormous. With this collaboration, Siemens and toolcraft are poised to make significant strides in the process industries, aerospace, and energy sectors. They are also exploring applications in mechanical engineering and medical technologies, where the unique properties of porous materials can offer tremendous advantages.

In the near future, Siemens and toolcraft intend to offer training programs, under their AMbitious initiative, to share expertise and help other industries adopt these innovative structures. Their goal is to push the boundaries of what additive manufacturing can do, expanding its role from prototyping and small-batch production to full-scale industrial applications.