Fraunhofer ILT will present three additive developments at Formnext, November 17–20, 2026: a millisecond LMD powder-flow switch, a titanium electrolyser element with graded porosity, and an LPBF wrench containing a printed strain gauge. Their common aim is not merely complex geometry, but integrating a separate component, assembly or process step into manufacture.

Stopping powder without moving parts

In laser material deposition, powder can continue flowing when the laser pauses briefly along a complex path. That creates waste, contamination and safety risk. Fraunhofer says mechanical shut-offs can take more than a second and wear, which is too slow for dynamic LMD or EHLA.

The Fluidic Powder Switch diverts powder into a collection vessel directly at the nozzle using the Venturi principle. Control gas creates negative pressure at a constriction, allowing switching without moving components in the powder path. It can also select multiple materials and adjust mass flow in steps. The institute claims more than an order-of-magnitude faster switching and control-gas cost more than three orders below the value of powder saved.

Fraunhofer says first customers already use the switch in series production. That is stronger than a laboratory prototype, but the public release gives no customer, cycle count, powder system or maintenance data. Savings must therefore be measured for each powder flow, toolpath and recovery route.

Designed porosity in pure titanium

The second demonstrator treats pores as a functional gradient rather than a defect. The LPBFCells project makes an electrolyser porous transport layer from pure titanium, with dense and permeable zones. A monolithic part can combine transport layer, flow field and support instead of joining separately sintered layers.

The institute expects lower contact resistance and faster geometry iteration. Electrolysers and fuel cells are primary applications, with filters and turbomachinery also suggested. The demonstrator does not yet disclose cell efficiency, pressure drop, corrosion life or serial cost, so integration benefits cannot yet be quantified.

A sensor inside the printed part

The third development is an LPBF wrench with an integrated strain-gauge layer. Inkjet, aerosol-jet or pad printing can deposit sensor layers during or after the build. Under load, it can report deformation and stress in real time while placement inside the part protects it from abrasion and thermal exposure.

The concept supports condition monitoring and predictive maintenance, but Fraunhofer itself notes that robust processes and suitable sensor materials are still lacking. Formnext will show a functional prototype, not a qualified serial product. Calibration, temperature drift, signal routing, repairability and sensor life remain critical questions.

Editorial conclusion

All three developments point in one industrial direction: AM gains value when it integrates process function, material transition or measurement, not just shape. The powder switch is closest to production; the titanium PTL is an application demonstrator; and the smart wrench is a functional prototype. Distinguishing those maturity levels matters more than grouping them under one 'smarter printing' label.