Metal additive manufacturingAbout Exafuse
Exafuse engineers and manufactures solutions for large, complex and high-value metal components. We combine materials engineering, a purchased CNC-based LMD platform, a purpose-built robotic LMD system developed in-house, SLM/LPBF, process development and inspection planning—from the first feasibility question to a repeatable manufacturing route.
Clients speak directly with the engineers assessing their project. New enquiries are reviewed quickly so that missing information and the most useful next step become clear early.
The part defines the route—not the machine already on the floor.
Company
How to start
The first discussion does not need confidential drawings. Non-confidential facts are often enough to choose the right process and the right technical contact.
Why Exafuse was created
Exafuse is the metal additive manufacturing brand of ThinkIng - Additive Technology GmbH. The company was established in 2019 from the research and start-up environment around Ruhr University Bochum.
From the beginning, the team understood that demanding metal-AM projects do not end at the laser. Material compatibility, component access, kinematics, heat input, path planning, fixturing, post-processing and inspection all determine whether an experiment can become a reliable manufacturing route.
Exafuse was therefore not built as a conventional print bureau. Our purpose is to engineer the complete route around the component and, where required, adapt the machine, sensing or software to the task.
Co-founder and Managing Director Julian Krell completed his doctorate in materials engineering at Ruhr University Bochum. His materials background shapes how Exafuse assesses alloys, heat input, wear, finishing and the evidence required for a component.
Manish Sharma was involved in the company’s technical development from the beginning and joined as an engineer. His master’s work at Ruhr University Bochum focused on control systems for Laser Metal Deposition. Today, he works particularly on LMD/DED process development, process monitoring, image analysis and data-supported process assessment.
The combination of materials engineering, control and data engineering, and machine development remains central to the way Exafuse works.
Technical development
Our equipment evolved in response to real component constraints. Each expansion addressed a different limit: more scale, more freedom of movement or more geometric detail.
For large-scale material addition, repair and circumferential cladding, Exafuse bought its first CNC-based LMD platform. Additional rotary axes support rotational applications, while scanning, path planning and process observation were treated as parts of the complete system from the outset.
Complex contours, changing processing angles and difficult-to-reach surfaces required additional degrees of freedom. Exafuse therefore began developing and building its own robotic LMD system. Robot, positioners, fixturing, scanning, sensing, path planning and control are configured as one coordinated system around the component.
Since 2024, SLM/LPBF has complemented the large-format LMD routes. Powder-bed manufacturing suits applications where fine features, internal channels, lattice structures or compact functional integration matter more than high-volume local material addition.
Exafuse can now assess three distinct routes. The right choice depends on component function, geometry, material, post-processing, quantity and the evidence required for the application.
View technology and equipmentFrom an open research question to a manufacturing route
Technical knowledge does not have to be rebuilt at every handover. Not every project needs all five stages; we recommend only the work required to support a sound decision.
We align the component function, base material, geometry, load, quantity, timing and inspection or acceptance needs.
Where a direct manufacturing quotation would be premature, the material and process direction can be tested through calculations, coupons, test walls, demonstrators or controlled trials.
Parameters, path strategy, fixturing, scanning, sensing, monitoring and, where required, the kinematics or machine concept are adapted to the application.
Depending on maturity, the result may be a trial part, functional prototype, demonstrator or customer component with planned post-processing.
Inspection features, documentation and acceptance criteria are aligned with the component function and project risk.
When a research direction becomes a commercial customer project, scope, quotation, responsibilities, deliverables and acceptance criteria are defined as a separate assignment. Where external specialists perform machining or inspection, the interfaces and responsibilities are stated transparently in the project scope.
Research with an industrial direction
BreitbahnDED investigates wider and more uniform LMD/DED tracks, multispot optics, process stability and control with the aim of making large-area deposition more productive and more controllable.
View BreitbahnDEDEIS-KW connects additive tooling concepts with intelligent cooling and heat management for forging tools. The project treats SLM/LPBF, LMD, sensing, temperature control, wear assessment and industrial validation as one connected challenge.
View EIS-KWHow we work
Working with Exafuse
Direct technical responsibility, short coordination paths and an honest process recommendation shape the first review.
You speak with the people who assess the material, process, equipment route and project scope. Important context is not diluted through multiple sales and handover layers.
New enquiries normally receive a response within 24 hours on business days. It confirms our understanding, identifies missing information and recommends a useful next step; it is not automatic feasibility approval.
We combine the short decision paths of a technology-driven start-up with clear engineering responsibility.
When a standard process is not enough, we also assess component access, kinematics, fixturing, scanning, path planning, sensing, monitoring and control.
Our objective is not to force every enquiry into additive manufacturing or keep a particular machine busy. We identify technical limits, missing evidence and commercial risks early, then recommend the most robust route for the task.
We keep internal coordination lean—not the engineering review.
Start confidentially
Anonymised information about the component, material, dimensions and objective is often enough to identify the next technical step.
Sensitive drawings, CAD data, customer names or process information do not need to be included in the first message.
We do not require an Exafuse NDA template. Before confidential information is exchanged, we can review and sign suitable customer-provided confidentiality agreements. The file-transfer method and access arrangements are then agreed for the project.
The website intentionally does not provide a public upload field for confidential project files.
Start a confidential enquiryThinkIng - Additive Technology GmbH
One organisational foundation supports two clearly defined additive manufacturing fields.
Exafuse focuses on metal additive manufacturing, LMD/DED-LB/M, SLM/LPBF, repair, modification, laser cladding and additive-subtractive process chains.
Creative Polymer focuses on large-format polymer FDM printing, 3D modelling, surface finishing, painting and assembly.
Visit Creative PolymerThe clear division gives each brand a defined application focus, while the wider ThinkIng organisation brings together practical experience in metal and large-format polymer additive process chains.
Direct contacts
Julian Krell and Manish Sharma cover different technical questions and can be contacted directly.
Julian reviews material direction, process feasibility and the commercial scope needed for a technically useful quotation.
Manish handles R&D discussions on process monitoring, image analysis and data-supported LMD/DED evaluation.
