During the last years, additively-manufactured large components experience an increasing demand in the field of aerospace, energy industry, mechanical and tool engineering but also in the field of rail vehicle construction. These include components for housings, machine elements, tools but also structural and reinforcing elements made of varying materials such as Ti-, Fe-, Ni- up to Al-based alloys. Especially for large, highly loaded structures, high material efficiency as well as excellent material properties without defects are of enormous importance. Derived from this, the use of lasers in buildup welding is ideal, since filler materials can be applied in precise coordination with the radiation with defined mixing as well as high final contour proximity.

A major challenge with such components is the generally long process time, which requires a high degree of process robustness and repeatability. The residual stresses introduced in the process can have a particularly disadvantageous effect. In order to ensure a stable processing, simplified simulation models with acceptable computing times can therefore help. The basic procedure of such modeling will be presented in this talk. In addition, the extension and adaptation of the system technology makes it possible to digitize the additive structure and, hence, to engage directly in occurring process deviations. Finally, selected large AM components will be presented in the lecture.