Introduction -- State of the art -- Preliminary considerations -- Experimental development of the AMMID process -- Cross-sectional investigation -- Application and economic viability of the AMMID process chain -- Summary -- Outlook.

In this dissertation a new process chain for the Additive Manufacturing of Mechatronic Integrated Devices (AMMID) is described, which provides a new way to manufacture 3-dimensional electronic devices based on the SLS process using laser direct structuring (LDS) and metallization. The AMMID process chain meets the rising demand for highly functionalized parts, increasing individualization and shortening development cycles for electronic products. The content Provides an extensive review of the rapidly expanding field of additively manufactured electronics Material model, that describes the distribution of additive particles in a polymer matrix Provides further understanding on laser activation with fine metal powder additives for selective metal plating Presents the new AMMID process chain which can be used to produce MID based on the SLS process Shows the possibility to apply the AMMID process chain to materials such as TPU and resin-based materials Verifies the technology readiness of the AMMID process chain on functional demonstrator parts Contains a detailed and explicit cost model to calculate SLS part cost in the AMMID process chain The author Friedrich Wilhelm Proes studied mechanical engineering with a focus on product development, materials and production at the Technical University of Hamburg. There he received his doctorate in 2022 under Prof. Dr.-Ing. Claus Emmelmann (Institute for Laser and System Technologies - iLAS). During his time as a docoral candidate, he worked as a research assistant at the iLAS and as a key account manager at the LZN Laser Zentrum Nord GmbH, later Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT.