#IamDAP: Clemens Müller

Hi Clemens! You studied Materials Engineering in Aachen. What ultimately led you to Additive Manufacturing and the DAP?

It was a mixture of things. I was previously at the IEHK, but didn’t have the opportunity there to write a thesis in my specialisation ‘Materials Engineering of Metals’ and be employed as a doctoral student. A friend of mine who was working as a student assistant at DAP introduced me to Additive Manufacturing. Later, I got my first hands-on experience through an internship at Trumpf and the AM I module – and I was hooked. That’s when I started looking for a job as a student assistant at DAP. I ended up working for Stephan Koß, and one thing led to another: my hiwi position turned into a master’s thesis, and before I knew it, I was staying on for my doctorate. And the rest, as they say, is history.

At DAP, you’re part of the Hybrid Process Chains group. What exactly does your work focus on?

I mainly work with the Okuma MU-6300V Laser Ex, a hybrid machine that combines conventional machining with laser-based Directed Energy Deposition (DED). The market – especially in laser cladding – is moving more and more towards repair and refurbishment using AM. That’s why my machine plays a key role in establishing comprehensive process chains at DAP, covering everything from damaged parts to additive repair and final finishing.

In addition to hybrid process chains, another major focus of my research is metal matrix composites (MMCs). In my first publicly funded project, StReMa, I investigated the development of MMCs for wear-resistant coatings in stamping tools and achieved some very promising results.

My third focus is deep rolling within hybrid process chains, particularly in applications involving additive manufactured coatings and components. In all these areas, I’m particularly interested in process interfaces and the sustainability aspect of these technologies.

What can MMCs and deep rolling actually do?

The field of MMCs in Additive Manufacturing is still in its infancy. The ability to embed hard particles in a molten metal matrix opens up a massive range of possibilities. Whether it’s grain refinement, controlling phase formation, or creating ultra-wear-resistant coatings, MMCs have potential in almost every industry.

Deep Rolling is another powerful tool for improving component properties in multiple ways. It smooths rough surfaces after AM, introduces residual stresses, and increases hardness and strength near the surface. Another key benefit is that it can close small cracks and reduce porosity in coatings. This makes it especially valuable when working with MMC coatings, where defects can be a major challenge. By combining laser cladding with sdeep rolling, we can significantly enhance coating quality and performance, expanding their potential applications across industries.