Fused Deposition Modeling (FDM): The FDM technology is an additive manufacturing process used for complex component geometries and in prototyping. Since these components are still inferior to injection molded parts in terms of their mechanical properties, the deposition of the individual filaments is checked using computer tomography to obtain information for optimizing the manufacturing process.

Layered Composite: This detail of a layered composite shows the structure of continuous glass fibers deposited layer by layer in 0°/90°/0° orientation. This manufacturing method finds its application for components in aircraft, boat, and automotive construction, as they have strength like metal alloys, but are much lighter. In the CT volume, one can clearly see the fiber orientation and reliably analyze the material for delaminations, voids, or deformations due to external influences (e.g. impacts).

Short-Fiber-Reinforced Polyamide: This specimen is made of short-fiber-reinforced polyamide welded by ultrasound. The orientation of the fibers is an important criterion for the strength of a component. With computed tomography, the fiber orientation can be completely determined in a three-dimensional volume. Previously, this was only possible using very complex micrographs, which do not allow a full three-dimensional view. The method is also suitable for the optimization of injection molded components (determination of fiber orientation and -length) and the validation of process simulations.

Foams: Foams are mainly used for thermal insulation, but also in lightweight construction. They can be optimized for their respective purpose by influencing the size and distribution of the pores in the manufacturing process. This is a foam sample in the size of a corn kernel. Figure 1 shows the complete CT volume, which is digitally cropped in Figure 2, revealing the pores. In image 3, the negative view is used. The material is masked out and the air regions are visualized in color to examine the pore structure. It can be clearly seen that the pores decrease in size from the inside to the outside. The CT software can be used (among others) to calculate the volume and shape of each individual pore in relation to its position. With this data, it is possible to optimize the manufacturing processes according to the requirements and to influence the mechanical or thermal insulation properties.