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
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?
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?
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?
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?
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
Fraunhofer Institute for Production Systems and Design Technology