Sustainability and Quality Assurance

Deposition Welding for Repair and Reconditioning

Is it possible to automate the additive repair of tools and molds?

Individual and complex tools and molds can be repaired efficiently and, in a material-friendly manner with a high degree of automation using deposition welding.

Our solution

  • From 3D scan to CAM planning to the repaired component
  • Anti-wear coatings and functional coatings
  • Technology scouting, consulting and feasibility studies for your repair application


Your benefits

  • Reduce costs by reusing components
  • Upgrade instead of repair: Improve product properties through better materials and processes
  • High material flexibility with low component distortion and minimal impact on the base material

Digital Twins for Feedback to Design

What data is needed to optimize design decisions?

Information on the recycling of tools is provided at the end of a product's life. This allows conclusions to be drawn about product design and sustainability goals to be met.

Our solution

  • Develop individual targets for feedback to design
  • Identify feedback cycles between use and recovery of tools and molds through to their development
  • Capture and analyze requirements from a product perspective


Your benefits

  • Evaluation of data: better information in development
  • CO2 savings and compliance with regulations (e. g. secondary materials, recycling quotas)

Pressure Flow Lapping of Internal Contours

How can internal contours be processed in the best possible way?

Additively manufactured components and molded parts offer a high degree of design freedom. Powder residues and poor surface qualities often cannot be eliminated or finished using conventional processes.

Our solution

  • Innovative finishing methods such as pressure flow lapping for finishing internal cavities
  • Feasibility studies and parameter studies for smoothing internal functional surfaces
  • Developing devices and processes for targeted machining in the µ range


Your benefits

  • Increased functionality and service life of components
  • Targeted machining of inaccessible areas

Development of Additively Manufactured Cooling Structures

How can temperature management be implemented quickly and efficiently?

Additive manufacturing enables the integration of complex cooling and / or heating structures in components with limited installation space.

Our solution

  • Internally cooled high-performance tools
  • AM-compatible design with internal cooling channels, grid or porous structures, heat pipes, etc.
  • Studies on material and cooling media (water, oil, CO2, N2, etc.)


Your benefits

  • Cooling close to contour
  • Made from one component - no seal required
  • Maximization of internal surfaces – very high cooling capacity

Extended Reality Consulting: From Analysis and Planning to Implementation

How can virtual or augmented reality be used?

For the use of XR, the requirements and goals of an application must be clearly defined. We support you in the digital transformation process as an independent partner.

Our solution

  • User-centered analysis of profitable use cases
  • Benchmarking of necessary hardware and software
  • Integration into existing IT systems


Your benefits

  • Knowledge about advantages and disadvantages of innovative extended reality applications
  • Proof of concept to increase efficiency of your product development
  • High user acceptance through early involvement

Integration and Contextualization of Complex Product Data

How does data exchange succeed between processes and services in heterogeneous systems?

An important component of knowledge transparency is the identification, analysis and contextualization of models and documents. Networking enables a better understanding of the interrelationships.

Our solution

  • Semantic analysis of domains
  • Evaluate restructuring, model and integrate product data
  • Analyze and create semantic architectures based on existing systems and infrastructure


Your benefits

  • Visibility, availability, reusability of domain knowledge
  • Data continuity between systems and preparation for cross-system analysis capabilities
  • Connect and enrich individual data to model and create implicit and explicit knowledge

IoT-Based Services Using AI Models

How to predict a critical condition of a machine tool?

Improve the efficiency of production processes using AI models. Data analytics optimize the manufacturing process and sensor data.

Our solution

  • Capture process data
  • Analyze existing processes
  • Evaluate process and sensor data through algorithms


Your benefits

  • Improved process reliability
  • Shorter processing times enhances efficiency.
  • Product quality is increased.

Context-Sensitive Extended Reality Assistance Systems

What context-sensitive information do workers need in the workplace?

By using AR technology, visualized instructions, trainings and information can be displayed directly in the workspace. This increases efficiency and safety.

Our solution

  • Analysis of profitable use cases as well as hardware and software
  • User-oriented integration into existing processes
  • Linking software already in use


Your benefits

  • AR in production increases efficiency
  • Real and virtual product are directly connected via AR
  • High acceptance among users through their early involvement

Sustainable Product System Development in Tool and Mold Making

How to meet the demand for sustainable tools and molds?

How to identify design dependencies through methodical analysis to optimize the development of sustainable tools and molds in the long term.

Our solution

  • Analyze product system boundaries and interdependencies of lifecycle phases
  • Modeling of system architectures as a basis for quantification of environmental sustainability parameters
  • Elaboration of integration possibilities into the existing product system development based on the 9R strategies


Your benefits

  • Develop more sustainable product systems to increase competitiveness
  • Increase circularity and thus resilience in unstable supply chains
  • Comply with laws and regulations (e. g. EU taxonomy)

Sustainable Tool and Mold Making through Digital Twins

How can missing ecological indicators be made transparent?

A Digital Twin creates sustainable distinguishing features for tool and die making.

Our solution

  • Benefit-centered development and conception of a Digital Twin
  • Linking ecological indicators and design parameters
  • Derive optimization recommendations through data-based identification of CO2 footprint reduction opportunities


Your benefits

  • Monitoring and early forecasting of sustainability indicators from product development to product use in the Digital Twin
  • Identify design levers in tool and mold making for early optimization of sustainability

Optimized Repair Planning in Tool and Mold Making

How can data analytics be harnessed for the area of maintenance, repair and overhaul?

Damage prediction by machine learning is made possible with the help of operating and tool data. For this purpose, data is sifted and possible evaluation options are analyzed.

Our solution

  • Link operating and tool data
  • Process large amounts of data and find suitable AI models for damage prediction
  • Design and prototype implementation


Your benefits

  • Support damage diagnostics
  • Predict damage and downtime
  • Improve repair planning through damage prediction

Parameter Consistency across Domain Boundaries of Tool Development

How to avoid early integration errors and reduce coordination efforts?

Identify individual data and model flows in development and develop solutions for integration between domains.

Our solution

  • Analysis of company-specific dependencies between domains and models
  • Technology evaluation for benefit-oriented integration of selected parameters (e.g. dimensions of tool holders)
  • Realization as demonstrator and support during implementation


Your benefits

  • Reduce costs through early error prevention during integration
  • Market advantage through faster customer-specific adaptation options
  • Independent consulting and implementation support

Sensor Integration by Means of Additive Manufacturing

What are the advantages of »smart« products in quality assurance?

The use of temperature and acceleration sensors in close proximity to the working area enables predictive wear monitoring of tools and products as well as quality assurance during operation.

Our solution

  • Complete additive manufacturing product development
  • Design of cyber-physical systems and replacement of classic sensor systems with printed electronics
  • Implementation of Digital Twins and development of context-dependent operator support


Your benefits

  • Efficient in-situ process monitoring
  • Timely predictive maintenance
  • Continuous condition monitoring
  • Quality assurance of process chains

Monitor the Wear and Tear of Equipment and Processes

How can unpredictable machine failures be detected at an early stage?

Condition monitoring of machine tools helps to predict machine failures. In this way, maintenance and repairs can be planned over the entire lifecycle of a machine.

Our solution

  • External sensors record internal control information
  • Monitor analysis of real-time information
  • Develop application-related Digital Twins


Your benefits

  • Logged machine operation during the entire lifecycle ensures transparency and high data security
  • Sensors detect the smallest damage and predict critical machine conditions
  • Efficient plant operation thanks to plannable maintenance measures

Virtual Commissioning in Extended Reality Environments

How to get a fast start with a simple setup of existing software?

We develop application solutions that make commissioning based on extended reality environments faster, more cost-effective and more efficient.

Our solution

  • Analysis of use cases, hardware and software
  • Integration of existing systems/robots into XR environments and into existing IT systems


Your benefits

  • Proof of concept demonstrates an increase in the efficiency of commissioning
  • Even non-experts can perform commissioning
  • Early involvement of all users ensures a high level of acceptance

Recycle and Reuse Tools After the Use Phase

Why do Digital Twins improve resource efficiency?

Joint development of decision support systems for choosing the appropriate end-of-life recycling strategy to increase resource efficiency.

Our solution

  • Analyze requirements and develop specification from concepts to implementation
  • Benefit-centric data architecture for Digital Twins of machines and plants
  • Develop decision logics for suitable R-strategies


Your benefits

  • Consider end-of-life reuse and recycling options individually
  • Improve resource efficiency and comply with regulations (e.g. secondary materials, recycling quotas)

Reuse of Components and Development of Variants

What is the role of extended reality-based collaboration in engineering?

We design (modular) systems for component reuse and configure modular systems in extended reality environments.

Our solution

  • Analyze lucrative use cases and identify necessary information
  • Implement modular systems
  • Model cables and hoses in 1:1 scaling


Your benefits

  • Proof of concept, with evidence of increased efficiency in product creation based on modular systems
  • Early defect identification and cost-effective elimination through reuse and modeling in 1:1 scaling
  • Import and export model data between XR and engineering tools