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Institut für Steuerungstechnik der Werkzeugmaschinen und Fertigungseinrichtungen
Institut
Team
Nistler, Maximilian

Maximilian Nistler

Herr M.Sc.

Wissenschaftlicher Mitarbeiter "Mechatronische Systeme und Prozesse"
Institut für Steuerungstechnik der Werkzeugmaschinen und Fertigungseinrichtungen

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+49 711 685 84515
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Seidenstr. 36
70174 Stuttgart
Deutschland
Raum: 5.037

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Fachgebiet

Additive Fertigung

Additive Fertigung von Schalungssystemen für leichte Betonteile
Inbetriebnahme von Maschinen für die Additive Fertigung

Publikationen

Veröffentlichungen:

2026
1. Kovaleva, Daria ; Nistler, Maximilian ; Verl, Alexander ; Blandini, Lucio: 3D Printed Recyclable Sand Formworks: A Zero-Waste Path for Lightweight Concrete Structures. In: Beton- und Stahlbetonbau Bd. 121 (2026), S. 111–125
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  BibTeX
  @article{https://doi.org/10.1002/best.70164, abstract = {Abstract On the path to a sustainable transformation of the built environment, the concrete industry requires solutions that integrate mass customization with rigorous resource efficiency. This paper presents the results of SPP 2187 Subproject 12, which focuses on the development of an automated, zero-waste formwork production cycle for complex lightweight concrete components. The technology utilizes Selective Binder Activation (SBA)—a powder-bed-based additive manufacturing process—to create water-soluble sand formworks from a mixture of silica sand and organic binder. Key developments include a large-scale 3D printing unit, a transparent CAD-to-machine-code computational workflow, and a robust material reclamation strategy that enables near-complete recycling of the formwork material. The technology's scalability and structural viability are validated through two prototypes: a 1.2 m functionally graded reinforced concrete beam and the Marinaressa Coral Tree, a 3.2 m tall architectural demonstrator exhibited at the 2023 Venice Architecture Biennale. The results demonstrate that this circular manufacturing approach can reduce concrete consumption by 60\% while eliminating formwork waste during production and reach a production output of 34 l/h, effectively placing it within the performance range of current industrial standards.}, author = {Kovaleva, Daria and Nistler, Maximilian and Verl, Alexander and Blandini, Lucio}, doi = {https://doi.org/10.1002/best.70164}, eprint = {https://onlinelibrary.wiley.com/doi/pdf/10.1002/best.70164}, journal = {Beton- und Stahlbetonbau}, number = {S1}, pages = {111-125}, title = {3D Printed Recyclable Sand Formworks: A Zero-Waste Path for Lightweight Concrete Structures}, url = {https://onlinelibrary.wiley.com/doi/abs/10.1002/best.70164}, volume = 121, year = 2026 }
  Link
  https://onlinelibrary.wiley.com/doi/abs/10.1002/best.70164
2. Kienzlen, Annika ; Nistler, Maximilian ; Riedel, Oliver ; Verl, Alexander: Additive Prozesse in der virtuellen Inbetriebnahme/Additive processes in virtual commissioning. In: wt Werkstattstechnik online Bd. 116, VDI Fachmedien GmbH and Co. KG (2026), S. 544–553
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  BibTeX
  @article{Kienzlen_2026, author = {Kienzlen, Annika and Nistler, Maximilian and Riedel, Oliver and Verl, Alexander}, doi = {10.37544/1436-4980-2026-06-82}, issn = {1436-4980}, journal = {wt Werkstattstechnik online}, number = 06, pages = {544–553}, publisher = {VDI Fachmedien GmbH and Co. KG}, title = {Additive Prozesse in der virtuellen Inbetriebnahme/Additive processes in virtual commissioning}, url = {http://dx.doi.org/10.37544/1436-4980-2026-06-82}, volume = 116, year = 2026 }
  Link
  http://dx.doi.org/10.37544/1436-4980-2026-06-82
3. Tsyharin, Mykola ; Nething, Christoph ; Nistler, Maximilian ; Funaro, Daniele P. ; Stolz, Andreas ; Verl, Alexander ; Blandini, Lucio: Additive manufacturing of biocemented porous structures using selective binding and active print bed compaction. In: npj Adv. Manuf. (Hrsg.) npj Advanced Manufacturing Bd. 3 (2026)
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  @article{noauthororeditor2013handbuch, author = {Tsyharin, Mykola and Nething, Christoph and Nistler, Maximilian and Funaro, Daniele P. and Stolz, Andreas and Verl, Alexander and Blandini, Lucio}, doi = {https://doi.org/10.1038/s44334-026-00084-x}, editor = {npj Adv. Manuf.}, journal = {npj Advanced Manufacturing}, language = {englisch}, number = 24, refid = {859299227}, title = {Additive manufacturing of biocemented porous structures using selective binding and active print bed compaction}, volume = 3, year = 2026 }
2025
1. Klingel, Lars ; Nistler, Maximilian ; Mantz, Daniel ; Werz, Martin ; Verl, Alexander: Online Real-Time Simulation for Collision Avoidance in Robotic Wire Arc Additive Manufacturing. In: Holder, D. ; Wulle, F. ; Lind, J. (Hrsg.) ; Holder, D. ; Wulle, F. ; Lind, J. (Hrsg.): Advances in Automotive Production Technology -- Digital Product Development and Manufacturing. Cham : Springer Nature Switzerland, 2025 — ISBN 978-3-031-88831-1, S. 76–87
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  @inproceedings{10.1007/978-3-031-88831-1_7, abstract = {In manufacturing processes involving industrial robots, collisions are a significant risk due to the high number of degrees of freedom. This is particularly the case in complex processes such as wire arc additive manufacturing, where metal is printed using a welding unit mounted on the robot. Simulations can be used before the operating phase to identify potential collisions between the industrial robot and itself, the workpiece clamping, or the workpiece. Even after intensive testing, a collision can still occur during the operating phase if any environmental condition differs from the simulation. This could be due to a change in motion caused by actual measured values or the modification of parameters by humans or an adaptive system. This work presents a concept for online real-time collision avoidance in robotic wire arc additive manufacturing. The concept is based on adopting simulations from virtual commissioning for the use in the operating phase. The concept is then realized with the help of a real industrial robot. The resulting solution's novelty is the virtual commissioning-based online collision avoidance of wire arc additive manufacturing with industrial robots.}, address = {Cham}, author = {Klingel, Lars and Nistler, Maximilian and Mantz, Daniel and Werz, Martin and Verl, Alexander}, booktitle = {Advances in Automotive Production Technology -- Digital Product Development and Manufacturing}, editor = {Holder, Daniel and Wulle, Frederik and Lind, Jannik}, isbn = {978-3-031-88831-1}, pages = {76--87}, publisher = {Springer Nature Switzerland}, title = {Online Real-Time Simulation for Collision Avoidance in Robotic Wire Arc Additive Manufacturing}, year = 2025 }
2024
1. Dietrich, David ; Jud, Oliver ; Kurth, Daniel ; Lechler, Armin ; Leipe, Valentin ; Nistler, Maximilian ; Reiff, Colin ; Schulte, Alexander ; u. a.: MoNA – Die modulare Werkzeugmaschine – Eine offene Forschungsplattform/MoNA – The modular machine tool – An open research platform. In: wt Werkstattstechnik online Bd. 114, VDI Fachmedien GmbH and Co. KG (2024), S. 170–177
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  @article{dietrich2024modulare, author = {Dietrich, David and Jud, Oliver and Kurth, Daniel and Lechler, Armin and Leipe, Valentin and Nistler, Maximilian and Reiff, Colin and Schulte, Alexander and Steinle, Lukas and Verl, Alexander}, doi = {10.37544/1436–4980–2024–05–6}, journal = {wt Werkstattstechnik online}, month = {05}, number = 05, pages = {170-177}, publisher = {VDI Fachmedien GmbH and Co. KG}, title = {MoNA – Die modulare Werkzeugmaschine – Eine offene Forschungsplattform/MoNA – The modular machine tool – An open research platform}, url = {/brokenurl#doi.org/10.37544/1436–4980–2024–05–6}, volume = 114, year = 2024 }
  Link
  /brokenurl#doi.org/10.37544/1436–4980–2024–05–6
2023
1. Blandini, Lucio ; Kovaleva, Daria ; Haufe, Carl Niklas ; Nething, Christoph ; Nigl, David ; Nitzlader, Markus ; Smirnova, Maiia ; Strahm, Benedikt ; u. a.: Leicht bauen mit Beton – ausgewählte Forschungsarbeiten des ILEK – Teil 2: Strukturleichtbau. In: Beton- und Stahlbetonbau Bd. 118, Wiley (2023), S. 320–331
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  @article{Blandini_2023, author = {Blandini, Lucio and Kovaleva, Daria and Haufe, Carl Niklas and Nething, Christoph and Nigl, David and Nitzlader, Markus and Smirnova, Maiia and Strahm, Benedikt and Bosch, Matthias and Funaro, Daniele and Nistler, Maximilian}, doi = {10.1002/best.202300026}, journal = {Beton- und Stahlbetonbau}, month = {04}, number = 5, pages = {320--331}, publisher = {Wiley}, title = {Leicht bauen mit Beton {\textendash} ausgewählte Forschungsarbeiten des {ILEK} {\textendash} Teil 2: Strukturleichtbau}, url = {https://doi.org/10.1002%2Fbest.202300026}, volume = 118, year = 2023 }
  Link
  https://doi.org/10.1002%2Fbest.202300026
2022
1. Nistler, Maximilian ; Kovaleva, Daria ; Tepper, Louis ; Blandini, Lucio ; Sobek, Werner ; Verl, Alexander: Camera-based Process Monitoring for Powder Bed Additive Manufacturing in Construction. In: Procedia CIRP. Bd. 107 : Elsevier BV, 2022, S. 534–539
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  @inproceedings{Nistler_2022, author = {Nistler, Maximilian and Kovaleva, Daria and Tepper, Louis and Blandini, Lucio and Sobek, Werner and Verl, Alexander}, doi = {10.1016/j.procir.2022.05.021}, journal = {Procedia {CIRP}}, pages = {534--539}, publisher = {Elsevier {BV}}, title = {Camera-based Process Monitoring for Powder Bed Additive Manufacturing in Construction}, url = {https://doi.org/10.1016%2Fj.procir.2022.05.021}, volume = 107, year = 2022 }
  Link
  https://doi.org/10.1016%2Fj.procir.2022.05.021
2. Kovaleva, Daria ; Nistler, Maximilian ; Verl, Alexander ; Blandini, Lucio ; Sobek, Werner: Zero-Waste Production of Lightweight Concrete Structures with Water-Soluble Sand Formwork. In: Buswell, R. ; Blanco, A. ; Cavalaro, S. ; Kinnell, P. (Hrsg.) ; Buswell, R. ; Blanco, A. ; Cavalaro, S. ; Kinnell, P. (Hrsg.): Proceedings of the 3rd RILEM International Conference on Digital Fabrication with Concrete (Digital Concrete 2022). Cham : Springer International Publishing, 2022 — ISBN 978-3-031-06116-5, S. 3–8
  - BibTeX
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  @inproceedings{10.1007/978-3-031-06116-5_1, abstract = {In the face of climate change and resource crisis, the construction industry can contribute to sustainable economic development by reducing its material consumption, emissions and waste. The application of lightweight construction principles in combination with circular production processes offers a comprehensive approach to this problem. The newly developed zero-waste formwork production method, based on the additive manufacturing of water-soluble sand mixture, enables to produce geometrically complex concrete structures and to reuse formwork material repeatedly in production cycles. This paper demonstrates the potential of this method for the production of the topologically optimised concrete single-span beam with spatial lattice structure (Fig. 1). First, a brief overview of the method will be given, followed then by a description of the design and production of the concrete component under the consideration of production parameters.}, address = {Cham}, author = {Kovaleva, Daria and Nistler, Maximilian and Verl, Alexander and Blandini, Lucio and Sobek, Werner}, booktitle = {Proceedings of the 3rd RILEM International Conference on Digital Fabrication with Concrete (Digital Concrete 2022)}, editor = {Buswell, Richard and Blanco, Ana and Cavalaro, Sergio and Kinnell, Peter}, isbn = {978-3-031-06116-5}, pages = {3--8}, publisher = {Springer International Publishing}, title = {Zero-Waste Production of Lightweight Concrete Structures with Water-Soluble Sand Formwork}, year = 2022 }
3. Kovaleva, Daria ; Nistler, Maximilian ; Blandini, Lucio ; Sobek, Werner ; Verl, Alexander: Rezyklierbare Sandschalungen – Auf dem Weg zur Kreislaufproduktion leichter Betonbauteile. In: Beton- und Stahlbetonbau Bd. 117, Wiley (2022), S. 333–342
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  @article{Kovaleva_2022, author = {Kovaleva, Daria and Nistler, Maximilian and Blandini, Lucio and Sobek, Werner and Verl, Alexander}, doi = {10.1002/best.202200009}, journal = {Beton- und Stahlbetonbau}, month = {04}, number = 5, pages = {333--342}, publisher = {Wiley}, title = {Rezyklierbare Sandschalungen {\textendash} Auf dem Weg zur Kreislaufproduktion leichter Betonbauteile}, url = {https://doi.org/10.1002%2Fbest.202200009}, volume = 117, year = 2022 }
  Link
  https://doi.org/10.1002%2Fbest.202200009
4. Wulle, Frederik ; Gorke, Oliver ; Schmidt, Sarah ; Nistler, Maximilian ; Tovar, Günter E.M. ; Riedel, Oliver ; Verl, Alexander ; Weber, Achim ; u. a.: Multi-axis 3D printing of gelatin methacryloyl hydrogels on a non-planar surface obtained from magnetic resonance imaging. In: Additive Manufacturing Bd. 50, Elsevier BV (2022), S. 102566
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  @article{Wulle_2022, author = {Wulle, Frederik and Gorke, Oliver and Schmidt, Sarah and Nistler, Maximilian and Tovar, Günter E.M. and Riedel, Oliver and Verl, Alexander and Weber, Achim and Southan, Alexander}, doi = {10.1016/j.addma.2021.102566}, journal = {Additive Manufacturing}, month = {02}, pages = 102566, publisher = {Elsevier {BV}}, title = {Multi-axis 3D printing of gelatin methacryloyl hydrogels on a non-planar surface obtained from magnetic resonance imaging}, url = {https://doi.org/10.1016%2Fj.addma.2021.102566}, volume = 50, year = 2022 }
  Link
  https://doi.org/10.1016%2Fj.addma.2021.102566

Maximilian Nistler

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