FRAUNHOFER INstItUtE FOR PROdUctION tEcHNOlOgy IPt...IPT is committed to assisting the global...
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FRAUNHOFER INSTITUTE FOR PRODUCTION TECHNOLOGY IPT 2016 ANNUAL REPORT
Transcript of FRAUNHOFER INstItUtE FOR PROdUctION tEcHNOlOgy IPt...IPT is committed to assisting the global...
F R A U N H O F E R I N s t I t U t E F O R P R O d U c t I O N t E c H N O l O g y I P t
2016ANNUAL REPORT
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2016ANNUAL REPORT
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CONTENTS
4 Foreword
Profi le
6 In Profi le: The Fraunhofer IPT
7 To Consider the Entire Process
8 Our Formula for Success:
Technology plus Human Resources
11 Mission Statement
12 Organizational Chart
14 Equipment
16 Facts and Figures
Our Network
18 Board of Trustees
19 The Fraunhofer-Gesellschaft
20 Excellent Cooperation
22 Spin-offs
26 International Activities
Our Trends
28 Networked, Adaptive Production
32 Digitization and Networking
36 Additive Manufacturing
Our Business Units
42 Turbomachinery
46 Lightweight Production Technology
50 Tool and Die Making
54 Optics
58 Life Sciences Engineering
Our Competencies
64 Non-Conventional Manufacturing Processes
and Technology Integration
64 High Performance Cutting
65 Fine Machining and Optics
65 Precision Technology and Plastic Replication
66 Fiber Reinforced Plastics and Laser System Technology
66 Production Metrology
67 Production Quality
67 Strategic Technology Management
68 Operative Technology Management
End-of-Year Review
69 Fairs
69 Conferences
70 Doctoral Theses
70 Awards
71 Publications
72 What happened after the fi re
in the WZL machine hall?
73 References
74 Editorial Notes
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FOREWORD
Dear readers and friends of the Fraunhofer IPT,
2016 was an exciting year: the development of Industrie 4.0
has made further headway, in the manufacturing environ-
ments of our partner companies as well as at the Fraunhofer
IPT itself. The focus has been very much on digitization and
the establishment of networks, not only in the media but
also in the facilities and laboratories of our institute and our
partners at the RWTH Aachen Campus. Many research and
development projects are trying to establish how the new
emerging challenges can be best addressed and overcome.
Key events include the approval for our High Performance
Center on “Networked, Adaptive Production“, a joint initiative
of the Aachen-based Fraunhofer Institutes IME, ILT and IPT
with the RWTH Aachen University and currently ten industrial
partners. It is our common objective to develop a “Smart
Manufacturing Network“, a platform for the exchange
of digital production data. New software tools, network
functionalities and data structures will create a new level of
transparency in the interactions between man, machine and
product. We ultimately aim to summarize all production data
in a single digital representation, which will allow to make the
production of highly complex and customized components –
including even biological products – more fl exible and more
effi cient. 80 percent of the new High Performance Center’s
operating costs will be split evenly between the federal state of
North Rhine Westphalia on one side and the industrial partners
on the other, the Fraunhofer-Gesellschaft will contribute the
remaining 20 percent.
But as we all know: just when everything seems to proceed
nicely as planned, the unforeseen throws a spanner in the
works. This is what happened on the night of 4 February
2016 when the machine hall of our closest partner in research
and development, the Laboratory for Machine Tools and
Production Engineering WZL at the RWTH Aachen University,
was completely destroyed in a devastating fi re. Our own
research facilities and admin buildings only just escaped this
fi re in their immediate neighbourhood, for which we must
thank the extraordinary efforts of the Aachen Fire Brigade.
The WZL, meanwhile, was less fortunate, losing a large part
of its research facilities: machines, equipment, workshops,
measuring technology, a workshop for trainees and much of
its IT infrastructure.
Immediately and without any hesitation, the staff of the
Fraunhofer IPT went to help their distressed colleagues
wherever they could. It was only the close professional
cooperation and the high level of personal commitment of
IT experts from both institutions – which went way beyond
the call of duty – that ultimately allowed the WZL to preserve
the bulk of its digital data and to restore a fully functioning
IT infrastructure within the shortest possible time frame. As
Fraunhofer IPT executive, but also in my capacity as the Chair
for Manufacturing Technology at the WZL whose institute was
badly hit by the catastrophe, and on behalf of my colleagues
Christian Brecher, Robert Schmitt and Günther Schuh, I would
once again like to thank everybody wholeheartedly who
provided their support during these dark days.
Our thanks go equally to our clients, our partners and our
friends who have maintained their ties to the Fraunhofer IPT
for many years and who have provided their help and active
support to the WZL in their hour of need. Dare I say that we
are even a little proud of this community which does not
only share our passion for production technology but which,
as we have discovered once more, is a reliable friend at all
times, good and bad. We are therefore going with renewed
confi dence into the year 2017 and are looking forward to
many successful, innovative and exciting projects in research
and development.
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke
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From left to right:
Prof. Dr.-Ing. Robert Schmitt
Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Prof. Dr.-Ing. Christian Brecher
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c.
Fritz Klocke
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The Fraunhofer IPT has decades of experience in the produc-
tion technologies it utilizes in order to provide companies with
a strong basis for the digitization of production processes,
machine tools and equipment. Our technological expertise is
complemented by new production organization methods and
by the design of industrial software systems. The portfolio of
the Fraunhofer IPT extends from the evaluation and design of
technologies and process chains through planning and control
concepts to quality management control circuits. The institute
currently employs around 450 people who are dedicated
to applying their creativity to methods, technologies and
processes for a connected, adaptive production.
To consider the entire process rather than considering produc-
tion activities as individual operations, our work involves look-
ing at all production processes and the links between all the
elements of the overall process in their entirety – from research
and development through the acquisition of raw material and
services to the fi nal production stages and assembly.
Industries, products and technologies
Our business units combine the skills and the knowledge
of the individual departments, the Fraunhofer CMI and our
partner institute at the RWTH Aachen University, the Labora-
tory for Machine Tools and Production Engineering WZL. This
interdisciplinary view – which is informed by and aligned with
the perspective of industrial researchers – allows us to
approach and develop solutions which require thinking
beyond the narrow confi nes of any particular discipline.
Our range of services refl ects the needs, requirements and
challenges of a number of industries, technologies and
product groups:
• Automotive industry including suppliers
• Energy
• Life sciences
• Mechanical engineering
• Optical industries
• Precision engineering and microtechnology
• Turbomachinery
• Tool and die making
Technologies that provide a cutting edge
We put great importance on our continuous contacts and
exchanges with industrial corporations and the permanent
updating of our equipment. This allows us to ensure that we
always remain abreast of the latest technological trends and
developments – and that we can provide you with that all-
important competitive edge in your production technologies.
Our laboratories and production facilities feature state of the
art technology and cover an area of 5,000 m². The entire
Fraunhofer IPT occupies an area of app. 9,000 m².
IN PROFILE: THE FRAUNHOFER IPT
Anybody who wants to launch his products and serv ices successful ly on today’s g lobal markets must learn
to exceed his own l imitat ions and to shape the process of change, thinking on his feet and remaining for
ever wi l l ing to adapt himself to the cont inuously changing requirements.
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TO CONSIDER THE ENTIRE PROCESS
Research and development
Right at the early phases of product emergence – the research
and development phase – we can use our expertise to help
our customers identify new technologies, create concepts
and develop prototypes. We place a great deal of importance
on getting equipment, material and processes to perform
optimally, giving our client’s products the best chances of
competing in the market.
Purchasing
Whatever a company cannot make itself, it buys in from its
suppliers. Companies need to be able to rely on their suppliers
to provide top quality goods and services at reasonable prices,
so we take a close look at their supply base and the services it
provides. We structure the purchasing market for our clients,
help them to choose the right partners and develop individual
courses of action using tried-and-tested methods in order to
optimize their purchasing costs.
Production
The Fraunhofer IPT is seen by its clients as an experienced
partner for all issues related to production – and not without
good reason. Whether we are determining their status quo,
analyzing their production concept, selecting technology,
designing a system, or developing, optimizing and implement-
ing processes, they can rely on our motivated team of experts
representing different disciplines and many years of expertise.
We never look at concepts, technologies and systems in isola-
tion, but see them within the context of our client’s industrial
practice.
Management
In some situations, it becomes necessary to critically review
one’s fundamental management processes, the technology
strategy or the strategic and operative management as a
whole. We analyze structures and processes at all phases of
research and development, purchasing and production and
help our partners to develop a new, more promising approach
without abandoning best practices. We consider it particularly
important that their employees stand fi rmly behind any
changes, especially in sensitive areas.
On behalf of our c l ients, we develop and opt imize solut ions for modern product ion fac i l i t ies . Rather than
consider ing product ion act iv i t ies as indiv idual operat ions, our work involves looking at a l l product ion
processes and the l inks between al l the e lements of the overal l process in their ent i rety: When we analyze
our c l ient’s processes, we take in everything from research and development through the acquis i t ion of
raw mater ia l and serv ices to the f inal product ion stages. At the same t ime, we keep an eye on al l the re-
levant business and management processes.
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OUR FORMULA FOR SUCCESS: TECHNOLOGY PLUS HUMAN RESOURCES
We fi rmly and unconditionally believe in professionalism, part-
nership and effi ciency. We did not discover the importance of
these values for the purpose of phrasing a mission statement,
but in the daily routines of our Institute. For many years, these
principles have guided and informed the work of everybody
at the Fraunhofer IPT. The Fraunhofer IPT therefore provides
its employees with an excellent working environment and a
platform for their professional and personal development,
enabling them to assume a wide range of responsibilities at
the Institute, in academic science or other research institu-
tions, in the industry and in the wider society. The Fraunhofer
IPT is committed to assisting the global knowledge transfer, to
ensure that society as a whole will eventually benefi t from the
skills and the expertise of gifted scientists.
Carreers start at the Fraunhofer IPT
The basic principles of human resource management have
changed little since the Fraunhofer IPT was established
more than 50 years ago: it is our objective to provide young
scientists with a comprehensive project work experience and
to allow them, during this period of roughly fi ve years, to
complete their doctoral theses. In the space of fi ve years, some
of our employees may become Group Managers or Business
Field Managers and, subsequently, assume the responsibilities
of a Head of Department. They remain on average for another
fi ve years at the Institute, which means that at least one such
vacancy arises in any given year, providing a talented young
scientist with the opportunity of meeting the challenges of
managerial responsibility.
In order to help them reach these objectives, the employees
of the Institute are immediately – starting with the moment of
their arrival – subjected to an intensive training and preparation
schedule designed to allow them to accomplish their future
tasks. For this purpose, we use – in close cooperation with
the WZL of the RWTH Aachen University – the “Karrierepool
WZL Aachen PS GmbH”. This personnel consulting service
has been designed to support the scientifi c members of staff
at the Fraunhofer IPT and the WZL in planning the next steps
of their careers and in implementing these career plans. The
organization establishes contacts between the young scientists
and corporations in search of suitable candidates for their R&D
departments and managerial positions. Nearly all members of
our scientifi c staff are taking advantage of these services to
plan their subsequent careers. In 2016, 26 of our young scien-
tists have left the Institute for a job in an industrial corporation.
Professional personnel marketing to combat the lack of
skilled employees
Due to this personnel policy of ours, we need to recruit about
25 young scientists per year to fi ll our staff vacancies. Despite
a general fall in the number of candidates over the past few
years, we have so far managed to fi ll these vacancies every
year. Almost a third of new employees already started working
at the Fraunhofer IPT during their studies as student workers
or writing theses. In the past few years, also the proportion of
candidates who completed their studies at universities outside
the Aachen region has substantially increased.
To ensure that the Fraunhofer IPT remains an attractive career
option on the increasingly competitive market for highly
qualifi ed graduate this is the objective of the staff recruitment
campaign that the Fraunhofer Gesellschaft has continued
last year in universities all across Germany. At the beginning
of each academic semester, posters were put up displaying
central motives of the “DOCH.“ campaign in university build-
ings, the Aachen town center and in buses that were going in
the direction of the Fraunhofer institutes.
On top of that, an extraordinary PR stunt caused quite a stir
on 16 and 17 November 2016: employees and students of the
Fraunhofer IPT and ILT performed improvised theatre sketches
More than 450 highly committed and creat ive people are current ly helping the Fraunhofer IPT to achieve
i ts v is ion and to implement i ts var ious projects . Al l of the Inst i tute’s employees contr ibute their sk i l l s and
knowledge to cross-departmental , interdisc ip l inary teams: our f lat-hierarchy organizat ional structure
which ref lects the duty of each indiv idual to assume responsibi l i ty for the ent i re project creates space for
innovat ive ideas and ensures that our highly motivated workforce str ives hard to achieve the jo int ly iden-
t if ied object ives.
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on the “Campus Event“ at the RWTH Aachen University,
using spontaneity and creativity as well as some assistance
from professional actors and even the audience to portray the
Fraunhofer working environment through short and funny
scenes. Many of the students used the event for exchanges
with the employees of the two Fraunhofer institutes, inquiring
about working conditions, career paths and requirements. A
large picture album and a video trailer helped to spread news
of the event all over the social media.
“Virtual Reality“ plays an increasingly important role in staff
recruitment drives. The Fraunhofer IPT joined this trend in late
2016 when they – together with a professional fi lm crew –
produced a 360-degree video, allowing viewers to undertake
a “virtual stroll“ through the Institute. Applicants can gain
some initial experience of the Institute’s working environment,
its workshops and laboratories, and even “meet“ some of
the staff members. The video can soon be accessed on the
Institute’s website, video platforms and social media.
In November 2016, the inaugural “Fraunhofer Hiwi-Day“
was hosted as part of the Fraunhofer program to attract and
nurture young talent. The central admin offi ce had invited
students – including some from the Fraunhofer IPT – for a
two-day event to Berlin to provide them with information
about Fraunhofer career opportunities. The students could
also participate in skill training events and creative workshops
and were given the opportunity of networking with other
young Fraunhofer scientists from all over Germany.
Throughout the year, the Fraunhofer IPT also conducted regu-
lar information meetings for students and young graduates,
giving them an opportunity of fi nding out more about the
Institute and its many faces during a personal visit. The stu-
dents were also given the chance to inquire about career paths
at the Fraunhofer IPT and to establish some personal contacts
in informal discussions with the Institute’s staff members. In
cooperation with the RWTH International Academy, two ad-
ditional one-day meetings with presentations and guided tours
in English were conducted specifi cally for foreign students.
Excellent conditions for young engineers
In order to allow our male and female members of staff to
reconcile their careers and family lives more effectively, the
Fraunhofer IPT is offering them part-time occupation schemes.
Some young parents in our scientifi c staff have gone on
parental leave, taking advantage of the chance to share the
fi rst few months of their children’s lives with their partners.
The Fraunhofer IPT has also established a “parent-child offi ce“
to allow young parents an early return into employment. The
Fraunhofer IPT’s management is keen to assist its employees
in their search for nursery day care centers and child care for
school holidays or emergencies.
Professor Fritz Klocke was delighted to present Emely Harnisch
with the fi rst ever “TALENTA speedup“ diploma after she
had become the fi rst graduate from our institute to success-
fully complete this new Fraunhofer program. The two-year
“TALENTA speedup“ program is designed to provide women
scientists with “free spaces“ to develop their careers, with
comprehensive qualifi cation options in different fi elds and
with opportunities of networking alongside other women
within the Fraunhofer community. The program aims to
support the candidates in their ambition to fully exploit their
potentials, becoming executives or renowned experts in their
chosen fi elds. The next TALENTA candidates have already been
picked: Laura Niendorf, Ulrike Hermens and Malena Schulz
have joined the program this year.
Employee Survey – Analysis and continued improvement
In November 2015, the Fraunhofer IPT had participated in
the Fraunhofer-wide employee survey, the results of which
were published in February 2016. Roughly one year later,
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the Institute has completed a comprehensive process of
transformation, answering legitimate criticism with concrete
reforms. Four working groups on the topics of working hours,
occupational stress, doctoral dissertations and leadership
structures had proposed new concepts that were subsequently
implemented.
The group on working hours developed “fl exitime“ and
“trust-based fl exitime“ models as well as a new electronic
system of timekeeping that would also be suitable for people
who are working from home. The new fl exitime model was
implemented on 1 January 2017 through a formal company
agreement for a trial period of one year, following which it
will be reviewed and, if necessary, improved and adjusted.
Another working group tried to determine which additional
tasks were preventing employees from concentrating on their
core project work and how the administrative system could
be streamlined. Furthermore, a CRM group was established
and assigned to explore new ways of managing customer
data and their protection. The third working group proposed
the introduction of stricter rules and regulations for the
career management of post-graduates, guaranteeing Ph.D.
candidates a detailed feedback report about their academic
prospects after two years and, in the event that this initial
assessment has been positive, a right to academic mentoring
and to an intensive supervision of their dissertations. The way
in which the academic executives provide these mentoring
and supervision services will also be assessed as part of their
performance review. The fourth working group, chaired by
a professional expert from the Fraunhofer HQ, developed a
new set of leadership guidelines for the Fraunhofer IPT. These
guidelines defi ne the mission and the purpose of leadership,
stating clearly where responsibilities begin and where refl ec-
tion may be needed.
New performance assessment criteria were developed that will
allow the implementation of the new guidelines into the rou-
tine processes of the Institute. Training courses for executives
have also been designed, and executives and employees will
get regular opportunities for direct exchanges. An anonymous
dual-track feedback function has also been installed.
The reforms that were introduced following the employee
survey have been embedded in a process of continuous
improvement and will be duly monitored. Regular voluntary
in-house surveys and a strong commitment to internal com-
munication will make sure that the voices of our employees
will continue to be heard and that suggestions of how to
improve our processes will get a fair hearing.
On 23 September 2016, the Fraunhofer IPT hosted the 6th
“IPTinside“ one-day information event, this time under the
title “Networked Adaptive Production – What Lies Behind
It?“ In speeches and presentations, employees of the Institute
provided insights into the work of the various business units,
projects and strategically relevant initiatives. The event aimed
to stimulate cross-departmental networking, to inspire new
ideas through exhibitions and guided tours of the premises
and to familiarize the staff members with the concept of
“Networked Adaptive Production“.
Staff News
With effect from 1 January 2016, Dr.-Ing. Thomas Bergs has
fully concentrated his efforts on his responsibilities as Manag-
ing Director. The department for “High-Performance Cutting“
has since been headed by Dr.-Ing. Florian Degen.
With effect from 1 April 2016, Dr.-Ing. Eike Permin has taken
over the management of the department “Production Qual-
ity“, which was previously headed by Dr.-Ing. Markus Große
Böckmann.
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MISSION STATEMENT
Applied research and consulting
The task of the Fraunhofer IPT is to transfer research fi ndings
into economically viable and unique innovations in the fi eld
of production. The Fraunhofer IPT promotes and conducts
applied research, implements research results in an industrial
context, and provides relevant and effective consulting
services for the direct benefi t of industry, thereby contributing
signifi cantly to the competitiveness of companies.
Excellent and exceptional
The Fraunhofer IPT offers research and consulting services of
excellent quality on the basis of scientifi cally recognized proce-
dures and using state-of-the-art facilities. It is the goal of the
Fraunhofer IPT to achieve technological and opinion leadership
in its key focus areas with respect to contract research at both
a national and international level.
Transparent development guidelines
The Fraunhofer IPT works according to standard development
guidelines that coordinate the competence areas of the
individual departments and allow them to be integrated on a
project basis. Value is also placed on interdisciplinary collabora-
tion with recognized partners from industry and research. The
Fraunhofer IPT uses these synergies to offer system solutions
from a single source.
Qualifi ed and motivated employees
The performance of the Fraunhofer IPT is determined to a
decisive degree by the technical and social competence of its
staff. With a high level of commitment to the Institute and
exceptional motivation and professionalism in projects, the
employees of the Fraunhofer IPT are the foundation of our
success. The Fraunhofer IPT provides its employees with an
excellent working environment and a platform for professional
and personal development that equips them for challenging
tasks at the Institute as well as in other areas of science, in
industry and in society. “Knowledge transfer via people”,
i.e. external transfer of know-how gained at the Institute, is
actively encouraged at the Fraunhofer IPT.
Culture and values
The working environment at the Fraunhofer IPT is marked by
mutual respect, content transparency, openness, cooperative-
ness, understanding and trust. Collaboration with our partners
also rests on these values.
Customer orientation
All activities of the Fraunhofer IPT are carried out for the direct
benefi t of the customer. Customer satisfaction is a decisive
success indicator for the Fraunhofer IPT. Our capabilities and
professionalism in contract research lead to long-term partner-
ships.
Effi cient organization
The excellent work of the Fraunhofer IPT is based on optimum
internal procedures and sound use of methods. Administrative
and technical departments as well as marketing and media
design are actively incorporated into our services, enabling the
engineering departments to concentrate on technological and
methodological innovations. All organizational units of the
Fraunhofer IPT therefore play a role in ensuring the high level
of customer satisfaction.
Economic success and entrepreneurship
Economic success is crucial to the self-management and to the
strategic development of the Fraunhofer IPT. The independent
fi nancing of the Institute allows the technological potential
in future issues to be approached in a targeted way, so that
promising solutions may be derived for the customer.
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Executive director Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke
Managing chief engineer Dr.-Ing. Thomas Bergs MBA
ORGANIZATIONAL CHART
Process technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke
Fine machining and optics
Dr.-Ing. Olaf Dambon
High performance cutting
Dr.-Ing. Florian Degen
Non-conventional manufacturing processes
and technology integration
Dr.-Ing. Kristian Arntz
Production machines
Prof. Dr.-Ing. Christian Brecher
Production machines
Dr.-Ing. Michael Emonts
Fiber-reinforced plastics and laser systems technology
Dipl.-Ing. Dipl.-Wirt. Ing. Henning Janssen
Precision technology and plastic replication
Dr.-Ing. Christoph Baum
Production quality
and metrology
Prof. Dr.-Ing. Robert Schmitt
Production metrology
Dipl.-Phys. Niels König
Production quality
Dr.-Ing. Eike Permin
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Board of directors
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke, Prof. Dr.-Ing. Christian Brecher,Prof. Dr.-Ing. Robert Schmitt, Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Services
Dr.-Ing. Thomas Bergs MBA
Administration
Josef von Heel
IT
Jacqueline Barby
Building services
Dipl.-Ing. (FH) Dirk Nehr
External and internal communications
Susanne Krause M.A.
Cross-institute activities
Dr.-Ing. Thomas Bergs MBA
Technology management
Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Strategic technology management
Dipl.-Ing. Dipl.-Wirt. Ing.Markus Wellensiek
Operative technology management
Dipl.-Ing. Toni Drescher
Strategic research development
Dipl.-Ing. Axel Demmer
Strategic business development
Dipl.-Ing. Torsten Moll
High performance center
“Networked Adaptive Production“
Dr. rer. nat. Thomas Bobek
Strategic large-scale projects
and project centers
Dr.-Ing. Thomas Bergs MBA
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EQUIPMENT
Grinding and polishing machines and systems
– D40 diamond processing
– Polishing cell PM3
– Moore Nanotech 350 FG
– Moore Nanotech 500 FG
– Walter Helitronic Vision 400 L
– ABB IRB 4400 cell 1
– ABB IRB 4400 cell 2
– Satisloh AII
– Synchrospeed 120SL
– Loh Spheromatic
– Elb SWN 10 NC-K
Equipment for optics replication of glass and plastics
– Arburg injection molding machine 720 A
– Arburg injection molding machine with handling system
– Moore Nanotech 065 GPM
– Toshiba GMP-207 HV
– Toshiba GMP-211 V
– Laminating unit for roller stamping
– Roller stamping system
– HEX02
– FFUP
– Füller glass molding machine
Our laborator ies and product ion fac i l i t ies feature state of the art technology and cover an area of
5000 m². We put great importance on our cont inuous contacts and exchanges with industr ia l corporat ions
and the permanent updat ing of our equipment. In the year 2015 we invested an amount of 4.3 Mio Euro
for machinery and infrastructure.
Precision and high performance machining centers
– LT Ultra MTC 410
– Precitech Nanoform 250
– Weika
– Kern Micro
– Kern Pyramid Nano
– Mikromat 8V HSC
– Moore Nanotech 350 FG
– Leifeld PNC/CNC 75
– Monforts RNC 400 Laserturn
– Minimill
– DMG HSC55 linear
– CNC turning lathe - Gildemeister
– DMU50
– Maho 600 E2
– Alzmetall GS 1000
– Alzmetall AB 4/HAST
– Alzmetall AX 3-T
– Mössner Rekord
– Weiler Commodor 75 GS
– Weiler Primus LZ-G
– Mikron HPM 800U HD
– Monforts Unicen 1000
– MAP Pro.X 1000
Coating systems
– PVD coating system: Cemecon 800/9
– Galvanic nickel-phosphorus
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Lasers and auxiliary equipment
– Kern Evo
– Mikron HSM 600U
– Pro-PKD laser processing system
– Laserline diode laser systems LDF 4500-30 und LDF 5000-40
– Trumpf TruMicro 2220
– MA micro automation MicrohCell compact
– Trumpf TruCoax 2000
– Satisloh GI-3PL
– Mobile assembly cell
– Sysmelec assembly
– Häcker Automation VICO XTec
– Bolenz + Schäfer Portal
– IR Thermoforming test stand
– Kuka 360-2
– Boschert punching machine
– Alzmetall GX 1000/5-T-LOB
– Monforts LaserTurn
– Schuler-Beutler automatic punching press MSC-2000
– IPG fi ber laser
– Röders H²M
Specialist equipment
– Flexpaet
– LT Ultra MMC 1100-2Z
– LT Ultra MMC1300
– UHM
– HEGA ultrasonic cleaning system
– Mikro pullwinding system
– Schunk PowerCube SCARA robot
– Two-photon lithography systems
Nanoscribe Photonic Professional, Spectra Millenia Tsunami
– Double-belt press for FRP
– Robot-based multitechnology platform
for adaptive manufacturing “MIRA“
Data processing and simulation tools
– Triamec process monitor
– Zemax
Metrology and testing equipment
– Zeiss O-Inspect coordinate measuring machine
– Vibration test rig
– Surface roughness tester Taylor Hobson Form Talysuit Series
– Roundness measuring instrument Talyrond 262
– Coordinate measuring machine Werth Video Check IP
– Profi lometer FRT Micro Prof 100
– Micro hardness tester Leco M-400-H
– Hardness tester Wolpert UH-250
– Interferometer Zygo Verifi re, Wyko 6000 and Fisba μPhase
– Laser scanning microscrope Leica DM RXE
– Coordinate measuring machine Werth VideoCheck UA
– Mahr form tester MMQ 400 with optical scanning
– Wavefront measurement system Trioptics Wavemaster LAB
– Steinbichler Comet 5 white light scanning system
– Defl ectometry system 3D Shape SpecGage 3D
– White light interferometer Bruker NPFLEX and Contour GT-K
– Tool measuring machine Walter Helicheck Plus
– 3D microscope Alicona Infi niteFocus G4
– Mahr LD 260 Aspheric
– ilis StrainMatic polarimeter
– Keyence VHX-2000D microscope
– Zeiss Axio Imager A1m light microscope
– Contour and roughness measuring station
Mahr Marsurf LD 120
16
FACTS AND FIGURES
Mio €
30
25
20
15
10
5
0 2011 2012 2013 2014 2015 2016
Institute funding
National/Länder/EU funding
Research funding
Industry and business
Investment
Operational budget
Mio €
30
25
20
15
10
5
0 2011 2012 2013 2014 2015 2016
Budget
The fi nancial structure of the Fraunhofer-Gesellschaft distin-
guishes between operational and investment budgets. The
operational budget includes all personnel and material costs,
external profi ts and funding. The Fraunhofer-Gesellschaft’s
integrated fi nancial plan allows for transfers between budgets.
Operational budget
The operational budget amounted to approx. 27.6 million
euros in 2016, with 75 percent self-fi nancing.
Contract research
Profi ts generated through research in national and state fund-
ed projects decreased slightly, contributing 5.3 million euros to
the institute’s fi nancing (25 percent).
Profi ts generated through EU-funded projects increased to
2.7 million euros. EU projects are not fully-fi nanced, calling
for a contribution from the research institute. Fraunhofer
Institutes therefore limit their applications for such projects.
The Fraunhofer IPT took on projects in cooperation with
industrial partners which, combined with the profi ts from
contract research for industry, business and trade associations,
contributed 10.5 million euros to the institute’s fi nances
(50 percent).
17
Scientists
Non-scientifi c staff
100
80
60
40
20
0 ≤ 25 25-29 30-34 35-39 40-44 45-49 >50
Alter
Employees
450
400
350
300
250
200
150
100
50
0 2011 2012 2013 2014 2015 2016
Students
Scientists
Administration
Technicians/Designer
Employees
Personnel structures at the Fraunhofer IPT
An average of 450 staff was employed at the institute in
2016, with around 219 permanent staff members in scientifi c
and non-scientifi c departments (circa 56 percent scientifi c
staff). Remarkable is the high proportion of young employees
aged 25 to 35, mostly graduates starting their carreer at the
Fraunhofer IPT as scientiftic staff. Besides, there is a continu-
ously strong base of non-scientifi c staff of all ages.
18
Chairman of the Board of Trustees
Dr.-Ing. Stefan Nöken
Hilti AG, Schaan/Liechtenstein
The members of the Board of Trustees
Prof. Dr.-Ing. Eberhard Abele
Institute of Production Management, Technology and Machine
Tools of Technische Universität Darmstadt
Prof. Dr.-Ing. Kirsten Bobzin
Surface Engineering Institute, RWTH Aachen University
Dr.-Ing. Uwe H. Böhlke
Oerlikon Balzers Coating AG, Balzers/Liechtenstein
Dr.-Ing. Matthias Fauser, Grabenstätt
Hans-Dieter Franke
Management Partner MPower GmbH, Winnen
Felix Hoben
Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen
Manfred Nettekoven
Chancellor of the RWTH Aachen University
Dr.-Ing. Walter Pelzer
Ministry for Innovation, Science and Research
of the State of North Rhine-Westphalia, Düsseldorf
MR Hermann Riehl
Federal Ministry of Education and Research, Bonn
Prof. Dr.-Ing. habil. Ansgar Trächtler
Fraunhofer Institute for Mechatronic Systems Design,
Paderborn
BOARD OF TRUSTEES
Each of the Fraunhofer Inst i tutes has a Board of Trustees to advise the management of the Inst i tute and
the Management Board of the Fraunhofer-Gesel lschaft . They inc lude personal i t ies f rom academic l ife,
bus iness and government. The members of the Board of Trustees of the Fraunhofer IPT in the year under
rev iew were as fol lows:
19
At present, the Fraunhofer-Gesellschaft maintains 69 institutes
and research units. The majority of the 24,500 staff are
qualifi ed scientists and engineers, who work with an annual
research budget of 2.1 billion euros. Of this sum, 1.9 billion
euros is generated through contract research. More than
70 percent of the Fraunhofer-Gesellschaft’s contract research
revenue is derived from contracts with industry and from
publicly fi nanced research projects. Almost 30 percent is con-
tributed by the German federal and state governments in the
form of base funding, enabling the institutes to work ahead
on solutions to problems that will not become acutely relevant
to industry and society until fi ve or ten years from now.
International collaborations with excellent research partners
and innovative companies around the world ensure direct
access to regions of the greatest importance to present and
future scientifi c progress and economic development.
With its clearly defi ned mission of application-oriented
research and its focus on key technologies of relevance to the
future, the Fraunhofer-Gesellschaft plays a prominent role
in the German and European innovation process. Applied
research has a knock-on effect that extends beyond the direct
benefi ts perceived by the customer: Through their research
and development work, the Fraunhofer Institutes help to re-
inforce the competitive strength of the economy in their local
region, and throughout Germany and Europe. They do so by
promoting innovation, strengthening the technological base,
improving the acceptance of new technologies, and helping to
train the urgently needed future generation of scientists and
engineers.
As an employer, the Fraunhofer-Gesellschaft offers its staff
the opportunity to develop the professional and personal
skills that will allow them to take up positions of responsibility
within their institute, at universities, in industry and in society.
Students who choose to work on projects at the Fraunhofer
Institutes have excellent prospects of starting and developing a
career in industry by virtue of the practical training and experi-
ence they have acquired.
The Fraunhofer-Gesellschaft is a recognized non-profi t
organization that takes its name from Joseph von Fraunhofer
(1787–1826), the illustrious Munich researcher, inventor and
entrepreneur.
THE FRAUNHOFER-GESELLSCHAFT
Research of pract ica l ut i l i ty l ies at the heart of a l l act iv i t ies pursued by the Fraunhofer-Gesel lschaft . Foun-
ded in 1949, the research organizat ion undertakes appl ied research that dr ives economic development
and serves the wider benef i t of society. I ts serv ices are sol ic i ted by customers and contractual partners in
industry, the serv ice sector and publ ic administrat ion.
69Research
institutes and facilities in Germany
>2.1Research volume
24,500Employees
billion Euros
1.9Contract research
Federal funding <30%
Industrially and publicly funded research projects
>70%
billion Euros
20
In Aachen, we cooperate closely with the Laboratory for
Machine Tools and Production Engineering WZL of the RWTH
Aachen University in all our areas of expertise. The four senior
professors at the WZL are also the directors of the Fraunhofer
IPT. For decades now, the WZL has become a global synonym
for successful and future-oriented research and innovation in
the fi eld of production technology. In six different work areas,
research activities not only relate to fundamental theories and
fi ndings but are also adapted to industrial applications and
requirements. Furthermore, practical solutions are worked out
for the purposes of rationalising production.
Since spring of 2011, the Fraunhofer IPT supported the setup
of the Fraunhofer Project Group for Mechatronic Systems
Design in Paderborn. This project group worked on the
development of mechatronic systems for control engineering,
software engineering and product engineering. With effect
from 1 January 2016, the project group has been converted
into an independent Fraunhofer Research Institution for
and from 1. January 2017 into the Fraunhofer Institute for
Mechatronic Systems Design IEM. It is managed by Professor
Ansgar Trächtler.
International clients based in the USA are provided with on-
the-spot services via the Fraunhofer Center for Manufacturing
Innovation CMI in Boston.
EXCELLENT COOPERATION
Our membership in networks and cooperat ive projects g ives us the abi l i ty to solve interdisc ip l inary prob-
lems that would otherwise be beyond the scope of a s ingle inst i tute. The extens ive research spectrum
covered by the Fraunhofer-Gesel lschaft and the proximity to the RWTH Aachen Univers i ty g ives us access
to a far greater pool of knowledge to draw from.
Partners within the Fraunhofer-Gesellschaft
Within the Fraunhofer-Gesellschaft, we are a member of the
Fraunhofer Group for Production, an association of seven
Fraunhofer institutes that supports joint production-oriented
research and development projects. By combining a vast
variety of skills, competences and experience from individual
institutes, the Alliance provides its clients with integrated
one-stop solutions for product development, production tech-
nologies and systems, production processes and organization
as well as logistics.
In various other Fraunhofer Alliances (car manufacturing,
big data, additive manufacturing, lightweight construction,
imaging techniques), collaborate with other institutes, jointly
developing and marketing certain products and services within
the Fraunhofer-Gesellschaft.
On the RWTH Aachen Campus
On the Melaten campus of the RWTH Aachen University,
eleven research clusters, focusing on different areas, are cur-
rently under development, a project in which the Fraunhofer
IPT is also closely involved. The clusters will provide facilities
where companies and institutes can share their resources as
well as their knowledge and exploit synergies. The close geo-
graphic proximity will help them to coordinate their activities,
speed up research studies and improve their results, reducing
research costs and development costs.
21
The interface between science and manufacturing
The publicly funded research studies of the Fraunhofer IPT
receive support from two federal government ministries
(Education and Research, Economy and Energy), from the AiF
(the Federation of Industrial Research Associations), the federal
state of North Rhine-Westphalia, priority programs and special
research projects of the German Research Association DFG
and the European Commission:
Bilateral industrial projects
Short to medium-term contract research for industrial clients
with individual commissioning and joint, long-term problem-
solving projects in areas in which competition is minimal.
• Advice on technologies and methods
• Feasibility studies, analysis and assessments
• Techniques, machines and methods
• Prototype and machine construction
Public funding
Medium to long-term research projects carried out by a
network of research and industrial partners.
• Joint BMBF projects and EU projects
• Coordination of industrial project consortia
• Advice on national and EU research contracts
International projects
• Market evaluation
• Site establishment
• Know-how transfer
Strategic preliminary research
• Special research fi elds and fundamental projects contracted
out by the German Research Foundation (DFG)
• Participation in internal Fraunhofer development and
cooperation programs
• Studies, incl. standalone studies and studies that are
conducted by consortiums (together with manufacturing
corporations)
Services
• Market studies
• Design and small series
• Measuring activities
• Simulations
22
23
SPIN-OFFS
Aachen Center for Additive Manufacturing GmbH
The Aachen Center for Additive Manufacturing aims to enable
manufacturers of any size to integrate additive manufacturing
techniques profi tably into their production processes. The
ACAM community welcomes industrial partners and offers
them a wide range of services from project development to
staff training, feasibility studies, business consultancy and
access to information about the latest technologies.
Aixemtec GmbH
Aixemtec was established in November 2016 as a spin-off
of the Fraunhofer IPT. The company holds a license from the
Fraunhofer IPT for high-end assembly solutions, combining
the technological know-how of the Fraunhofer IPT in the fi eld
of optical system assembly with a customer-oriented service
concept. Its business model allows Aixemtec to provide its cus-
tomers with customized and sophisticated high-tech assembly
solutions for their manufacturing requirements.
Aixtooling GmbH
Aixtooling GmbH was founded in 2005 as a spin-off company
of the Fraunhofer IPT, with the vision of establishing precision
molding of optical glass as a standard technology for the
optical industry in Europe. The company has extensive com-
petencies in every signifi cant component of the process chain
for the replicative fabrication of precision glass optics. The core
competencies of Aixtooling GmbH are mold design, process
layout, and the fabrication of ultra-precision molding systems.
Invention Center
The Invention Center is located on the campus of RWTH
Aachen University and offers its partners access to technology
and opportunities of acquiring additional innovation manage-
ment qualifi cations while also providing optimized solutions
for technological challenges. In close coordination with the
TIME Research Area, the Fraunhofer IPT, the WZL and KEX
Knowledge Exchange AG, the Center is provides a technology
expertise that allows executives who are planning the future
of their manufacturing businesses to acquire a deeper under-
standing of the process from the original product idea via the
drawing board to the large series production in an industrial
environment.
The Fraunhofer IPT accommodates an increas ing number of start-ups which emerged from projects by
ambit ious employees of our inst i tute. The a im is to transfer appl icat ion-or iented research into concrete
industr ia l products and serv ices. Apart f rom that, further spin-offs have been successful ly act ive ins ide
their own off ices, laborator ies and machine hal ls for years.
24
INNOCLAMPInnoclamp GmbH
Innoclamp GmbH was established in 2015 in Aachen and is
specialized in the development and construction of automatic
clamping systems for the high-precision arrangement of
complex free-formed workpieces in machine tools and their
low-vibration fi xation. Innoclamp designs serial products as
well as unique clamping and automation solutions that have
been customized to meet the production requirements of
individual customers.
Innolite GmbH
Innolite GmbH was founded in August 2008 as a Fraunhofer
IPT spin off. Their core business has since been the ultra-
precision mold-making for the replication of plastic optics
as well as the direct manufacturing of metal optics. In 2009
the fi rst successful projects in the fi eld of plastic injection
compression molding were completed. A decisive contribution
to its customers was fi rst made possible thanks to the close
cooperation with its partners Arburg and the Institute of
Plastics Processing IKV of the RWTH Aachen University.
KEX Knowledge Exchange AG
The KEX Konwledge Exchange AG is a professional informa-
tion provider for technology and market information, founded
in 2013. Intelligent knowledge management systems,
complete accessibility to exclusive sources of information and
a unique network of experts allow effective scanning, scouting
and monitoring of technologies and markets. By means of a
demand-specifi c compilation and assessment of information,
the KEX is best placed to support a wide range of business
decisions.
MABRI.VISION GmbH
MABRI.VISION GmbH is a start-up company that develops
non-destructive optical measurement technologies for plastic
and glass products. The company designs and manufactures
measuring equipment for the off-line and in-line-quality
assessment of transparent and semi-transparent materials,
specifi cally focusing on the detection of barrier layers in
injection-molded or extruded products. The technology is
based on optical coherence tomography and enables the non-
destructive optical imaging of cross sections.
25
oculavis GmbH
oculavis GmbH was established in May 2016 and develops the
SHARE smart service platform which is designed to increase
the productivity of production and customer service activities.
The software supports the implementation of service processes
from the commissioning stage to troubleshooting through
mobile devices such as smart glasses. On request, oculavis
can also provide customized service projects around a wide
range of topics including smart glasses, mobile software and
augmented reality.
polyscale GmbH & Co. KG
polyscale develops, manufactures and distributes micro-struc-
tured components with optical features. A complex production
process allows new properties of structured surfaces, opening
various fi elds of applications. polyscale concentrates on LED-
driven technologies to develop and manufacture light guide
plates. polyscale’s light guide solutions provide customized
products for various industries to meet the highest possible
standards of performance, effi ciency and individuality.
son-x GmbH
son-x GmbH was founded in the summer of 2011 in Aachen,
Germany, as a spin-off company of the Fraunhofer IPT that
offers tooling systems for ultrasonic-assisted ultra-precision
machining. By means of this technology, son-x enables
direct machining of hardened steel and other materials with
single-crystal diamond tools in an optical quality. Through
the long-term experience of son-x’s employees in the fi eld of
ultra-precision machining and optics manufacturing, a strong
basis of know-how could be established.
WBA
Aachener Werkzeugbau Akademie GmbH
The WBA Aachener Werkzeugbau Akademie GmbH
concentrates the competencies of the Fraunhofer IPT and the
Laboratory for Machine Tools and Production Engineering
WZL of the RWTH Aachen University for tool, mold, and die
making companies. The WBA was founded in 2010 and owns
a tool shop for demonstration purposes. The corporation
offers continuing education programs as well as a master’s
program in collaboration with the RWTH Aachen University. In
the partnership model of the WBA, small and medium sized
companies are able to work on research projects that have a
practical orientation. Besides, the WBA answers technological
and organizational questions of companies of the industry.
26
INTERNATIONAL ACTIVITIES
Fraunhofer Center for Manufacturing Innovation CMI
The Fraunhofer Center for Manufacturing Innovation CMI
cooperates closely with the Fraunhofer IPT in many areas. In col-
laboration with Boston University, the Fraunhofer CMI conducts
advanced research and development leading to engineering
solutions for a broad range of industries, including biotech/
biomedical, photonics, and renewable energies. Engineers,
faculty partners, and students at the Fraunhofer CMI transfer
the results of basic research into advanced technologies that
meet the needs of both domestic and global client companies.
The primary focus is on the development of innovative high-
precision automation systems, instruments and medical devices.
This partnership allows the Fraunhofer IPT and CMI to
provide their clients with production technology research
and development services close to their production facilities,
while also creating the conditions for a sustainable technology
transfer between European and American manufacturers. The
Fraunhofer CMI works closely together with Boston University
and its offi ce on the BU campus is built right next to the Uni-
versity’s Manufacturing Engineering Department. The training
of highly qualifi ed engineers in an international environment is
also something they care about very deeply.
“Powertrain Manufacturing for Heavy Vehicles
Application Lab“ in Stockholm
A new consortium of powertrain manufacturers and research
institutions has been established in Sweden with a view
to strengthening and securing the competitiveness of its
Internat ional jo int ventures assume an ever growing importance for the Fraunhofer IPT. We cooperate
with top-qual i ty univers i t ies , internat ional ly renowned research inst i tut ions und global corporat ions on
many s i tes across the world in order to jo int ly pave the way for technological progress and development.
industrial members. The “Powertrain Manufacturing for Heavy
Vehicles Application Lab“ was established on 13 September
2016 by three Fraunhofer institutes – IPT, IWU and ITWM, the
Royal Institute of Technology in Stockholm, the Swerea KIMAB
and Swerea IVF research institutes (members of the research
network RISE – Research Institutes of Sweden), the Technical
University of Chalmers and the industrial manufacturers Scania,
Volvo Trucks and Sandvik Coromant. Under the projects of
the new center, the partners will develop technologies for the
mass production of components for the powertrains of heavy-
duty vehicles and improve conventional production processes.
The research cluster aims to use research commissions from
the industrial partners to strengthen the network between the
Swedish automotive industry, leading Swedish research institu-
tions, the Fraunhofer Institutes and their German client base.
“Fraunhofer Project Center for Design and Production
Engineering for Complex High-Tech Systems“ at the
University of Twente
The Dutch high-tech industry is growing rapidly and gener-
ates total annual revenues of more than 27 billion euros.
The “Fraunhofer Project Center for Design and Production
Engineering for Complex High-Tech Systems“ at the University
of Twente – FPC@UT for short – has been designed to supply
this large market for technological solutions and to make it
easier for Dutch companies to access new applications.
With its many years of experience in the development of pro-
duction technologies and engineering equipment for Industrie
4.0, the Fraunhofer IPT is now making a contribution to the
27
Dutch – and the FPC@UT’s – efforts of converting research
results into directly marketable products. The co-operation
of the Fraunhofer IPT with the partners of the University of
Twente and the Enschede-based Saxion University of Applied
Sciences is meant to strengthen the competitive positions
on either side and to help the German as well as the Dutch
“Smart Industries“ in the development or products that are
likely to do well on the international markets. Activities at the
Project Center started on 23 January 2017.
“Center for Embedded Bioanalytical Solutions“ in Dublin
In close coordination with the Dublin City University, the
Fraunhofer IPT is currently developing the “Center for
Embedded Bioanalytical Solutions“ in Ireland, a new focus
for contract research in the fi eld of micro-fl uidic bioanalysis
systems. The joint venture has been designed to develop
so-called lab-on-a-chip systems that are made from plastic.
While the Irish partners are in charge of technical design and
specifi cations for applications in – for example – medicine, en-
vironmental sciences and food technology, the Fraunhofer IPT
will commit its know-how in production technology. Another
Fraunhofer Institute – the CMI – will also make a contribution
to the project. The new “Fraunhofer Project Center for
Embedded Bioanalytical Solutions“ has been launched in the
spring of 2017.
Michel Klatte is Regional Manager for Asia
at the Fraunhofer IPT
The Chinese government is currently pursuing a “Made-in-
China 2025“ strategy, the fi rst of three stages in a plan to
take the country to the year 2050. The strategy is designed to
support Chinese joint ventures with foreign research partners
to achieve “innovation through cooperation“. The revenue
forecasts of reliable studies that were commissioned by large
industrial federations and industrial consultancies provide
more reasons for seeking to engage on the Chinese market.
In order to be preserve its abilities to react quickly and more
professionally to these developments, the Fraunhofer IPT has
established the new position of a Regional Manager Asia
and appointed Michel Klatte who has for several years been
responsible for the Institute’s industrial cooperation with the
Beijing Machine Tool Research Institute (BMTRI). In June 2016,
a three-year Memorandum of Understanding was signed with
the intent of providing a long-term basis for the cooperation
between the two institutions.
28
29
Over the past year, the Fraunhofer IPT has further sharpened i ts prof i le in the f ie ld of Industr ie 4.0 by
developing the idea of the Smart Manufactur ing Network, an important foundat ion for the future of
manufactur ing. Dr.- Ing. Thomas Bergs, Managing Director of the Fraunhofer IPT, expla ins the role that the
Fraunhofer High Performance Center “Networked Adapt ive Product ion“ wi l l be play ing.
NETWORKED ADAPTIVE PRODUCTION
Everybody is talking about Industrie 4.0 –
so what is the view of the Fraunhofer IPT?
Manufacturing companies are simultaneously living in two
worlds: in the real world of components, tools and heavy
equipment, but at the same time also in a separate virtual
world where process data and component data are stored.
It is the objective of Industrie 4.0 to close this gap between
real and virtual world and eventually to make it disappear
altogether. New model-based analytical methods and active,
adaptive automatic process control systems that are capable of
learning autonomously from past processes will make it pos-
sible to design more fl exible and more productive processes
and integrated process chains. Most companies can see what
will eventually be possible, but fi nd that they themselves have
barely started on the journey.
What is the Fraunhofer IPT doing to foster these
objectives?
Together with the two other Aachen-based Fraunhofer-
Institutes, we have established the High Performance Center
“Networked Adaptive Production“, which receives funds
from the government of the federal state of North Rhine-
Westphalia and its industrial partners. We are planning to use
this center for the construction of an open research platform
with six pilot lines where we can, in close coordination with
IT experts and engineering companies, explore new concepts
of digitalized production and subject prototype production
lines to practice-based tests. All elements of these pilot line
production systems will be mutually networked and integrated
into a single “Smart Manufacturing Network“, having been
connected with a Fraunhofer-operated cloud solution, the
“Virtual Fort Knox“. The concept has been designed in such
a way that it can be converted for use by other industries,
companies and process chains.
How can real world and virtual world
“grow together“?
The High Performance Center provides perfect conditions
for the creation of nearly complete virtual representations of
process or processing states – so-called “digital twins“ – along
the entire manufacturing chain, no matter the nature of the
individual application. Assistance systems allow the user to
access control and production data and to forward these
data immediately to the industrial process with the help of
technology apps where the data can be quickly analyzed and
optimized. All elements that are involved in this “Internet
of Production“ can freely communicate with one another,
making their data available all over the world. New data
analysis methods create the conditions required to discover
and eventually exploit new and so far unknown relationships
between machines, production systems, databases and
simulation systems. This will pave the way for the use of new
algorithms that enable “machine learning“ processes, creating
a world where production systems can autonomously adapt
themselves to changing conditions and requirements.
Contact
Dr.-Ing. Thomas Bergs MBA
Phone +49 241 894-105
30
The High Performance Center “Networked Adaptive
Production“ will be based in Aachen
The new High Performance Center “Networked Adaptive
Production“ has been designed to ease the introduction of
Industrie 4.0 into the energy, mobility and healthcare industries.
This was announced by Hannelore Kraft, Prime Minister of
the federal state of North Rhine-Westphalia, on the occasion
of the annual Fraunhofer Conference in May 2016 at Essen.
This plan, the PM emphasized, matches the digital agenda of
her government which supports and partly funds three such
centers in the federal state.
The High Performance Centers are meant to create – through
the cooperation of academic and non-academic researchers
with industrial companies – unique selling propositions on
the domestic and international markets and to strengthen the
international competitiveness of local companies. The three
Aachen-based Fraunhofer-Institutes IPT, ILT and IME want to
develop, in close coordination with the RWTH Aachen Univer-
sity and renowned industrial partners, production systems and
value-adding chains that comply with the principles of Indust-
rie 4.0 before validating their fi ndings in practice-oriented pilot
production lines. The idea is that networked production tech-
nology will generate fl exible, adjustable systems that make it
possible to design integrated manufacturing cycles for small,
customized series of various components – from the drawing
board to their eventual recycling – with cost structures that are
nearly identical to the structures of large series.
The High Performance Center “Networked Adaptive Produc-
tion“ aims to design more fl exible and more effi cient process
chains for the production of technologically complex, perhaps
also biological, products. Their comprehensive technological
skills and experience with individual processes and integrated
process chains will allow the three Fraunhofer institutes to
generate a nearly complete virtual representation of the
various process and processing states along the process chain.
The institutes are planning to apply suitable data architectures,
big data tools and cloud services to subsequently convert this
representation into actual technology applications.
The Aachen-based High Performance Center will have a
fi nancial volume of approx. EUR 6.5 million, 40 percent
of which will be shouldered by the federal state of North
Rhine-Westphalia, 40 percent by the industrial partners and
20 percent by the Fraunhofer-Gesellschaft. Companies with a
need to address specifi c issues will be given the opportunity of
joining the platform at a later stage.
Service-oriented architecture for the adaptive, net-
worked production in Smart Manufacturing Networks
With a view to the requirements of a future “Internet of
Production“, the Fraunhofer IPT developed a concept for an
intelligent production network. The main idea is the creation
of a so-called “Smart Manufacturing Network“, on whose
basis all elements – machines, production systems, databases
and simulation systems – can freely communicate with one
another. The operators are integrated into the system through
mobile devices such as tablets or smart glasses and can
interact directly and in real time with all sub-systems, control
them and access production data. Such decentralized and
dynamic systems make it possible to plan, implement and
repeatedly reconfi gure manufacturing processes and process
chains quickly and cost-effi ciently.
Smart Manufacturing Networks are linked to the so-called
“Virtual Fort Knox“, a cloud solution that has been developed
at the Fraunhofer IPA in Stuttgart. This solution has been
selected as the instrument for a safe exchange of data by the
members of the Fraunhofer Group of Production.
31
Through its service-oriented software architecture that
provides manufacturing process technology services within the
Smart Manufacturing Network, the Fraunhofer IPT has created
a new method of designing a more fl exible component
process chain: during the planning stage, a preliminary
process chain for the component is defi ned, which does not
yet specify the individual machines that will be used but only
the requirements such as assembly space, number of axes
and surface quality specifi cations. On the basis of measuring
data for the blanks and other conditions, the software will
then autonomously calculate the process data and select the
correct production machine in the given line by comparing
the requirements identifi ed in the planning stage and machine
availability. Only after this will the manufacturing data for the
specifi c machine be adjusted so that the production process
can be completed.
This process ensures a high level of fl exibility within the pro-
cess chain and at the same time a consistent documentation
of process parameters and results. The integration of tablets
and smart glasses gives the operators access to all informa-
tion they need to perform their jobs. The provision of such
information is important in situations where the process chain
cannot be automatically operated or where special authoriza-
tions are required.
ERP
OPC UA* InterfaceM2M-Communication ProtocolSOA
Service Oriented Architecture * Open Platform Communication Unified Architecture
PLM
Cloud(Virtual Fort Knox)
Smart Manufacturing Network (SOA)
SimulationRaw Part
Metrology
Milling
EDM
Employees
Component
Availability of process and production data
Technology database
CAx frameworkfunction blocks
Data analyticsDigital Twin
GeometryMaterialReal dataHistorical dataFunctional data
Functional assignment by CAx framework LMD
SLM
Laserstructuring
32
33
DIGITIZATION AND NETWORKING
Research inst i tut ions such as the Fraunhofer IPT have a responsibi l i ty of interconnect ing machines in pro-
duct ion networks, of recording and of process ing product ion data and of ensur ing that these data are
re- introduced to inform the manufactur ing process: in other words, a responsibi l i ty of paving the way for
a convergence, a “growing together“ of real and v i r tual product ion environments. This i s why the Fraun-
hofer IPT has establ ished a dedicated working group for digi ta l izat ion and networking processes.
Dr. Thomas Bobek, Chairman of this working group, explains what he and his colleagues are trying to achieve.
What benefi ts can a manufacturing enterprise
derive from digitization and networking processes?
The sine qua non of every manufacturing process is the
production of a component that complies with all specifi ed
tolerances. It is therefore important to record all data that may
provide evidence for the development of the component at
various stages of the process chain. Sensors in the production
equipment provide valuable information about vibration levels,
process forces and process temperatures that may cause a
possible violation of the specifi ed tolerance limits. Such infor-
mation can be used to optimize the manufacturing process or
to create a documentation fi le, for example in the production
of turbo engine components where expensive high-safety
components must be manufactured with the smallest number
of iterations.
What can be done with these huge amounts
of data?
All data from the manufacturing history are then used to
create a “digital twin“ that can be assigned – through
identifi cation systems – to the individual component. Every
recorded data set must be assigned to a unique place and
time, allowing the correct classifi cation of sensor data about
ambient temperature, machine vibration levels and process
parameters. Digital assistance systems support the members of
staff by indicating any divergence from the specifi ed process
conditions. Technology apps enable process developers and
operating staff to use their skills with greater effi ciency.
Visualization tools such as smart phones and smart glasses
provide their information in real time, allowing immediate
interventions in case anything goes wrong.
How would all that look in an industrial
production line?
Process developers need to adjust many parameters to
ensure that – for example – a 5-axis milling operation will
run smoothly and at the highest possible level of effi ciency.
Model-based simulations can provide important hints of how
to optimize performances. Software apps in simulated milling
processes, for example, are capable of virtually identifying
and highlighting critical sections of the process. Such features
allow the process developers to address a wide range of issues
before the fi rst trial run in the “real world“. Comparisons
between real data and their simulations represent powerful
tools of accelerating the optimization process – provided that
machine-integrated sensors, simulation tools and databases in
the “Smart Manufacturing Network“ have access to compre-
hensive data about components from past production runs.
Contact
Dr. rer. nat. Thomas Bobek
Phone +49 241 8904-149
34
Retrofi t for Industrie 4.0: vBox makes it possible
to equip existing machines for new challenges
In the world of Industrie 4.0, sensors must be able to pick up
and synchronize data in and around machines with very high
levels of accuracy. These data are then fed in real time into a
data processing network which enables the system to develop
an instant and autonomous response. Many companies are
afraid of losing touch with the latest technological develop-
ments and are replacing their fully functioning and relatively
new equipment with even newer machines that can be readily
connected to production networks.
The vBox of the Fraunhofer IPT now provides an alternative
strategy, allowing companies to retrofi t existing equipment
with network capabilities and to enable real time data
exchanges. The compact system can synchronize positioning
data as well as digital inputs and outputs with sensor data and
create visual representations, independently from the control
system in use and in full compliance with current industrial
standards.
Machine data and information about force, structure-borne
sound and acceleration are transmitted in real time and at
high levels of quality, revealing any fl aws in critical process
stages and allowing immediate interventions. On this basis,
companies can plan and optimize the work schedules of
individual operators and service engineers. The vBox can be
fully integrated into existing manufacturing execution systems,
making a key contribution to the provision of transparency in
production processes, an important feature of Industrie 4.0.
Flexible mechatronic clamping systems
with active vibration control
Industrie 4.0 production lines require the effective and ef-
fi cient processing of information, but the means of production
must also be physically capable of adjusting their geometrical
shape and their kinematics to the specifi c tasks of each new
operation. The accuracy of milling processes for example,
particularly the processing of oddly shaped components or
thin-walled components, can be badly affected by vibrations.
The “FixTronic“ project therefore aims to develop a
mechatronic system of stabilizing the equipment by reducing
process-induced vibrations and instabilities through active
vibration control and an adjustment of the machine spindle’s
rotational speed. The system is designed to enable the use of
more effective process parameters without compromising the
quality of the manufactured end products.
With adaptive control systems, workpieces of different geom-
etries can be accurately clamped. The integration of clamping
systems and machine tools into a single network allows the
effective monitoring of the workpiece stability, which means
that effi cient processing parameters can be safely applied
without subjecting the workpiece to any additional risks.
The new approach of the “FixTronic“ project converts the
workpiece itself into a “cyber-physical system“ – to use the
terminology of Industrie 4.0 – that carries information which
allows the product to autonomously control the system of its
own production.
The project is receiving funds with a total volume of
EUR 910,086.75 under the program “Lead Market Competi-
tion for Production.NRW“ in the period from July 2016 to
June 2018.
35
Smart glasses for a smoother information fl ow on the
shop fl oor
oculavis, a software that has been developed by the
Fraunhofer IPT to integrate smart devices into manufacturing
lines, has been successfully marketed since mid-2016 by the
eponymous spin-off company and successfully launched in
actual industrial environments. From 25 to 29 April 2016, the
Fraunhofer IPT demonstrated at the Hanover Industrial Fair
how the Robert Bosch Elektronika Kft. (Hungary) had used
the software solution for the purpose of training new staff
members on an experimental assembly line. Smart glasses,
it was shown, are a useful instrument for complex working
processes and perfectly illustrate the requirements of adaptive
networked production. They can assist the operators and
enable the introduction of applications such as mobile imaging
for quality assurance purposes and the integration of produc-
tion equipment through OPC-UA. Smart glasses are equipped
with a camera for stills and video images and with a display,
which means that they allow the immediate and direct visu-
alization of all elements within the working process. With the
help of these images, even new and inexperienced trainees are
in a position to learn and work autonomously.
The software can be used in conjunction with commercially
distributed smart glasses, provided they are equipped with
an Android operating system. A so-called process and
context editor can model individual steps of manual or hybrid
processes. The operators can then link their smart glasses with
the software via an app and perform the process steps in their
correct sequence.
This demonstrates that smart glasses can deliver more than
just manufacturing process optimization: they can also provide
quicker access to process-related information such as retooling
times and cycle times, helping to build up extremely short
quality control loops that may even integrate more than a
single operating site. In a subsequent step, underlying sources
and causes of errors may be analyzed with a view to creating
an integrated preventive risk management system.
36
37
ADDITIVE MANUFACTURING
The terms Addit ive Manufactur ing and 3D-pr int ing are often used to descr ibe the technology of bui ld ing
up components layer-by- layer on the bas is of 3D-data. Dr.- Ing. Kr ist ian Arntz, Head of the department for
“Non-Convent ional Manufactur ing Processes and Technology Integrat ion“, expla ins the chal lenges of
addit ive technologies and the advice the Fraunhofer IPT is g iv ing to companies that want to compete on
this market.
What must companies know before using additive
manufacturing processes?
The layered structure provides the designers with a high
level of freedom in the creation of component geometries.
On the other hand, the range of possible materials is rather
narrow, and the obtainable levels of precision and surface
quality are relatively low. The productivity of the processes
is determined by the size, the material and the geometry of
the components. The simpler and larger the component and
the higher the target quantity of the production run, the less
cost-effi cient the 3D-printing technology. New developments
look set to close this gap, but one must not expect production
volumes in the dimension of the automotive industry. It is also
uncertain what the technology does for the environment – the
materials, after all, are not easy to make, and their production
generally requires high energy inputs.
Does it make any sense to integrate additive
processes into mass series production lines?
As the paragraph above suggests, 3D-printing technology is
not meant to replace but only to complement conventional
production methods. The future belongs to an intelligent
combination of production technologies and to their integra-
tion into complex value-adding chains. Customized products
require networking and adjustable techniques, as illustrated
by the example of spare parts: 3D-printing is the perfect
technology for small quantities and irregular demand patterns.
It is also suitable for the customization of semi-fi nished
products. At the same time, however, production lines, too,
must develop to remain apace with events: the future belongs
to autonomous production lines that either operate in close
vicinity to the customers or customize standard components.
How can the Fraunhofer IPT help companies
that want to integrate additive manufacturing
processes into their production lines?
Over the years, the Fraunhofer IPT has acquired comprehen-
sive experience with many different production technologies.
We are familiar with their potentials but also with their limi-
tations. This experience is the core of our competence and
also informs the advice we give to our clients about additive
technologies and their introduction into existing production
processes. We take an integrated view, assessing the entire
value-adding chain, evaluating technologies in view of existing
process chains and helping in the selection of the individually
right option. Overall, we believe that additive techniques are
potentially benefi cial elements of process chain design and
optimization but do not offer standalone solutions. We always
strive to generate a realistic representation of the entire pro-
cess chain so we can introduce additive technologies where
they make sense: where they may serve to save time and
money.
Contact
Dr.-Ing. Kristian Arntz
Phone +49 241 8904-121
38
Additive manufacturing process chains
The Fraunhofer IPT is developing systems solutions for the
integration of additive technologies into new or existing
process chains, providing consultation and technical services
that range from technological feasibility studies to assistance
in the selection of the right hardware and the design of the
required industrial processes.
The Fraunhofer IPT is also conducting research into adaptive
software solutions for the selection, the application and the
monitoring of AM processes that are needed in the design of
CAx process chains and CAM modules for applications such
as laser deposit welding and in the assessment of potential
benefi ts and of process chains in additive manufacturing
technologies. For the operation and the integration of additive
technologies into the process chain, the Fraunhofer IPT uses
a self-developed CAx framework. Using defi ned “function
blocks“, digital twins of the components are created. This
strategy allows us to run the virtual components through
simulations and to base the downstream processing steps on
comparisons between virtual and real data.
Another element is the customization of AM production
processes for specifi c industries and product groups. Such pro-
cesses include the additive technologies themselves such as
powder-based or wire-based laser deposition welding, but also
pre- and post-processing subtractive techniques and hybrid
technologies with elements from either. Specially designed
additive technologies such as tape laying and micro-level
two-photon polymerization complement the technology range
of the Fraunhofer IPT. The IPT can support its customers with
processing strategies and production technologies that range
from high-gloss fi nishing to the processing of functional and
the removal of supporting segments, while comprehensive
optical and tactile measuring technologies guarantee compli-
ance with the highest possible quality standards.
3D meets FRP: More fl exibility for high-stress
components
Customization and adjustability must not necessarily confl ict
with robustness and stability: products that require both sets
of these seemingly contradictory features – such as car seats
and prostheses – will in the future be manufactured through a
combined use of 3D-printing technology and fi ber-reinforced
plastics. The use of 3D-printing technology allows the highest
possible degree of fl exibility in determining component shape
and function, while the FRP ensures the component’s stability
even under high levels of stress. The Fraunhofer IPT and its
industrial partners are currently exploring the potential of
such a combined process in the “LightFlex“ research project
which – with funds from the Federal Ministry of Education
and Research – is developing a photonic process chain for the
fl exible, generative, automated and cost-effi cient production
of customized hybrid light-weight components that are made
from fi ber-reinforced thermoplastics.
3D-printing technology allows nearly any degree of customiza-
tion and any functional design before the components are
reinforced with the FRP which gives them the required degree
of stress resistance. In order to increase this resistance even
further, the FRP components are made from so-called organic
sheeting – unidirectional semi-fi nished products – that are
combined through thermoforming with the 3D-printed
structure. The 3D-printed components are provided by the
industrial project partner, Wehl Group Sintertechnik GmbH
from Salach (Germany). The “LightFlex“ project involves
the conversion of the entire process chain into a networked
adaptive manufacturing operation, from the production of the
semi-fi nished product (by the Institute of Plastics Processing
(IKV) in Industry and the Skilled Crafts at RWTH Aachen
University and other partners) to the laser trimming by
Arges GmbH.
39
At the International Trade Fair for Composite Materials JEC
World 2016 in Paris, the partners presented the production
facility as well as a demonstration component that had been
produced with the innovative combination of manufacturing
processes.
The project receives funds from the Federal Ministry of Educa-
tion and Research (Reference Number: 03XP0013).
ACAM network starts with six research projects
The idea was an immediate hit: the “Aachen Center for
Additive Manufacturing ACAM“ – established in 2015 by
several Aachen-based institutes and technology fi rms under
the leadership of the Fraunhofer IPT und ILT – was still in its
start-up phase when companies from Germany, Austria, Japan
and Switzerland already agreed to join and to cooperate. At
the fi rst meeting of the industrial partners with representatives
from the six institutes and technology fi rms, the consortium
agreed on an ambitious program with six research projects
and twelve seminars for the year 2016.
16 industrial partners and the Aachen-based research network
are taking an integrated approach to the challenges of addi-
tive manufacturing, conducting projects on issues of design,
process technology and business management, training and
further education, feasibility studies, consultancy and tech-
niques for the acquisition of knowledge in a community of
experts. The most important elements of the additive manu-
facturing roadmap include initial joint research ventures that
were proposed by Dr.-Ing. Kristian Arntz from the Fraunhofer
IPT and Dr.-Ing. Johannes Witzel from the Fraunhofer ILT.
The ACAM industrial partners represent a broad product
portfolio from a similarly broad base of industries that includes
gas, steel, luxury watches, hybrid cars, tunnel drills and jet/
rocket propulsion engines. The ACAM industrial partners were
provided with “research vouchers“ during the initial confer-
ence of the consortium that allowed them to pick six out of
the nine proposed projects. With the large number of aspects
they involve, these projects refl ect the network efforts’ high
degree of integration. The topics range from the requirements
of an industrial process chain and an analysis or assessment of
production facilities to questions of how to qualify materials
for LMD and SLM processes, handling instructions for metal
powder and health and safety issues.
The seminars that will be offered as part of the joint venture
are similarly wide-ranging. Starting in May 2017, twelve
one-day and multi-day seminars will provide beginners as well
as experienced operators with fundamental knowledge about
additive manufacturing, skills in the use of standard-CAD
program and of AM-rules of construction or will assess the po-
tential of additive manufacturing in the foundry business. One
early highlight was the “Additive Manufacturing Innovation
Day“ on 23 June 2016, during which experts and partners of
the Fraunhofer IPT joined their ACAM partners to explore new
ideas for the technology in an informal and playful setting.
40
41
OUR BUSINESS UNITS
Being successful in the fi eld of production technology requires
the ability to overcome one’s limitations and the willingness
to react fast and fl exibly in the face of sudden changes. In our
business units we take a close look on the strategic demands
of different industries, being well known for our profound
knowledge of their individual needs and scopes and for driving
further developments.
In our business units we use the wide expertise of our depart-
ments and provide comprehensive solutions to our customers.
By continuously addressing the issues and challenges of our
project partners, we not only acquire the inspiration for our
future research studies but also develop our technological
know-how. This steady and intensive exchange enables us to
develop and to implement customized and innovative solu-
tions for the benefi t of our clients.
Depending on the task we employ our enhanced network
and involve partners, in particular the Fraunhofer CMI and
the Laboratory for Machine Tools and Production Engineering
WZL of the RWTH Aachen University. This enables us to solve
interdisciplinary problems.
For the latest information from our business units and for news about their service range, go to our web page:
www.ipt.fraunhofer.de/businessunits
42
43
TURBOMACHINERY
Higher effi ciency and lower emissions – these are the key
objectives in the development of modern turbomachinery.
Heat-resistant materials, complex geometries and integral
components are but a few of the features of turbomachines.
Pioneering approaches can frequently be implemented only
when new production methods are applied. In the Turbo-
machinery business unit, the Fraunhofer IPT explores and de-
velops robust and effi cient process chains and technologies for
the manufacturing and repair of turbomachinery components.
Our long-standing network of contacts provides us with access
to the know-how of other scientifi c and engineering facilities
in Germany. We maintain particularly close working relation-
ships with both the Fraunhofer Institute for Laser Technology
ILT and the Laboratory for Machine Tools and Production
Engineering WZL of the RWTH Aachen University.
The ICTM Aachen – International Center for Turbomachinery
Manufacturing, a joint initiative of the Fraunhofer IPT, the
Fraunhofer ILT and the WZL as well as the LLT of the RWTH
Aachen University, covers the entire technology portfolio of
these institutes, offering research and development services
for turbo engine manufacturers at the highest possible level
of excellence. In cooperation with highly renowned industrial
partners, the ICTM Partner Community was established to
accelerate the development of technological innovations and
their rollout in an industrial environment.
Our services
• Optimization of individual technologies such as milling,
grinding, laser material processing or water jet cutting
• Robust and adaptive design of integrated manufacturing
and repair process chains
• Machine characterization and process monitoring
to ensure stable processes
• Overall quality and risk management as well as technology
and market potential analyses
Contact
Dipl.-Ing. Daniel Heinen
Phone +49 241 8904-443
44
Methodological assessment of alternative blisk
manufacturing process chains
The replacement of assembled disks with BLISKs (Blade
Integrated Disks) has become a standard element of every
new turbo engine program. Different technologies can be
employed to manufacture such BLISKs: conventional milling
or electrochemical processes are currently the favorites, but
laser deposition welding, automated polishing and water jet
cutting provide viable alternatives. Companies fi nd themselves
constantly caught between confl icting objectives: what should
they prioritize when selecting their production technologies,
the lowest possible cost, the best possible quality, or the
shortest possible production time?
The Fraunhofer IPT and the WZL of the RWTH Aachen
University have implemented and evaluated seven process
chains to establish the most cost-effi cient confi guration of
manufacturing options for each individual case. Identical qual-
ity requirements for alternative process chains to manufacture
a BLISK from Inconel 718 allowed the researchers to subject
these process chains to meaningful cost and cycle time com-
parisons. These comparisons applied an integrated evaluation
approach that was based on economic as well as ecological
objectives and that needed to be adjusted fl exibly to account
for different framework conditions.
With this strategy, the researchers generated reliable insights
into the structure of the process chain and were able to iden-
tify the most cost-effi cient process chain depending on the
target production quantities. Their result can, if required, be
broken down to the resource level of individual process steps.
Superelastic shape-memory alloys enhance
process stability
The market demands ever more complex integrated compo-
nents with ever thinner walls made from high-performance
materials, but such materials are often diffi cult to machine
and require sophisticated processing technologies. Due to
their complex geometries and the inaccessibility of some of
their sections, integrated components often require milling
equipment with long projections. These, however, frequently
generate vibrations that create fl aws on the surfaces of these
high-precision components which result in short tool lives, low
material removal rates and high rates of rejection.
In the “NiTiProstab“ project, the Fraunhofer IPT and its indus-
trial partners are experimenting with the use of superelastic
shape-memory alloys to attenuate these tool vibrations. The
project aims to improve the dynamic process stability of fi nish-
ing operations, which would make manufacturing processes
more cost-effi cient and more economically viable. The research
is concentrated on improving the rigidity and attenuation
levels of the tool system.
The use of highly attenuating NiTi materials inside the
clamping sleeve of the tool system can serve to stabilize the
fi nishing process of sensitive component-tool-combinations.
Such materials can improve component surface qualities,
extend tool lives and shorten processing times. It is planned to
establish a system for the development of alloys and clamping
sleeves, but also to enhance the general understanding of the
industrial processes at work and to implement an analytical
software designed to gain insights into the fl exibility and
resilience of the milling equipment.
The SME Innovation project will receive funds with a total
volume of approx. EUR 600,000 in the period from May 2016
to April 2018.
45
MTU intensifi es cooperation in the “Competence Center
for Compressors and Manufacturing“
MTU Aero Engines has declared his intention to cooperate
even more closely with the Aachen-based institutes and to
extend the scope of their joint ventures from the current
production of components for high-pressure compressors and
low-pressure turbines to include prototypes for sophisticated
testing equipment for aerodynamic and thermodynamic com-
ponents. During the conference of the Steering Committee
on 13 July 2016, MTU announced the decision of the partners
to move their cooperation to a broader base within their
“Competence Center for Compressors and Manufacturing“.
MTU has closely cooperated with the Aachen-based institutes
for many years, and its fi rst joint ventures with the WZL go
back to the early 1970s. The “Competence Center for Com-
pressors and Manufacturing“ was established in 2007, while
MTU has also participated in the Fraunhofer innovation cluster
“TurPro“ and assumed the responsibilities of a Premium
Partner in the ICTM partner community.
ICTM Aachen – International Center for Turbomachinery
Manufacturing
The Fraunhofer IPT and ILT, the WZL and the LLT of the RWTH
Aachen have already recruited 30 highly renowned industrial
partners for their “ICTM Aachen – International Center for
Turbomachinery Manufacturing“. The Center will concentrate
on researching processes of manufacturing and repairing
turbo engine components.
The ICTM Aachen was established to accelerate innovations,
to help experts in the build-up of networks and to create a
culture of excellence in pre-market research. Network partners
include turbine manufacturers, large corporations and SMEs
from all parts of the process chain. Together, they aim to
develop technological innovations and to introduce them
into industrial environments through a strategy of long-term
cooperation.
The ICTM partner community intends to develop answers to
challenges such as advanced machining, additive manufactur-
ing and digitization for the manufacturing and the repair of
turbo engine machine components. Research projects will be
conducted on an annual basis, and the Center also plans to
host an ICTM Conference every two years in Aachen. A pro-
gram of seminars and in-house workshops will complement
the range of events.
The Center will not receive any government funding, thus
becoming a member of the small club of truly independent
networks that have been spun off from the highly successful
Fraunhofer Innovation clusters. Originally, the researchers had
planned to concentrate on jet turbines only, but the focus
of their efforts was soon extended to include the production
of turbo engines for non-aeronautical applications such as
energy, oil and gas production as well as the automotive
industry. Companies still have the opportunity of joining the
network.
More details: www.ictm-aachen.com
46
47
LIGHTWEIGHT PRODUCTION TECHNOLOGY
The use of lightweight materials offers a great many
advantages. Apart from the saving of weight and the gain in
strength, these include, for example, chemical resistance in
the case of components made from fi ber-reinforced plastics
and special electromagnetic characteristics, making them
interesting for a broad range of electrical or medical applica-
tions. Fraunhofer IPT’s business unit ‘Lightweight production
technology’ supports companies in the mass production of
lightweight products and thus in the economic production
of effi cient, more environmentally friendly products that are
affordable for the end customer. For this purpose we develop
and plan innovative manufacturing systems and technolo-
gies for such diverse industries as the automotive industry,
aerospace, energy and medical technology or consumer goods
industry.
In order to achieve the economic mass production of large
quantities for lightweight construction too, we bundle our
long lasting experience in production processes, manufactur-
ing methods, measuring systems and process automation as
well as technology and quality management with our broadly
diversifi ed knowledge of techniques for the processing and
machining of fi ber-reinforced plastics and metals. Beyond that
we offer our customers interdisciplinary solutions through
integration in proven research networks such as the Aachen
Center for Integrative Lightweight Production AZL. In this way
we secure decisive advantages for our customers and partners
in production.
Our services
• Development of multi-material and fi ber-reinforced
structures for manufacturing environments
• Development and automation of systems for the manu-
facturing of multi-material and fi ber-reinforced structures
• Handling of fl exible semi-fi nished products
• Development of systems and processes for the automatic
joining and separation of light-weight components
• Online quality assurance systems
• Functional integration in multi-material and fi ber-reinforced
structures
• Planning of manufacturing environments for the production
of lightweight components
Contact
Ramon Kreutzer M.Sc.
Phone +49 241 8904-507
48
Automated system for the customized processing
of fi ber-reinforced thermoplastics
On 4 May 2016, the Fraunhofer IPT together with its
development partners, HBW-Gubesch Thermoforming
GmbH and Bond-Laminates GmbH was awarded the JEC
Americas Innovation Award in the category “Process“ for the
development of an automated technology which is capable of
manufacturing customized components from fi ber-reinforced
thermoplastics. The winners were honored for their develop-
ment of an automated system of manufacturing stress-
optimized fi ber-reinforced thermoplastics from unidirectional
fi ber-reinforced tapes that only produces a small number of
rejects.
The innovative standalone system developed by the
Fraunhofer IPT also allows the online-welding of large series
of unidirectional tapes, enabling the production of stress-
optimized organic sheets with locally different strengths and
reinforcements. The facility operates with delivery speeds of
up to 1 m/s and is capable of producing organic sheets with
overall widths of up to 1 m. Designers can customize the
laminates to each application and any required level of stress
resistance by freely adjusting the fi ber patterns. The facility
is the fi rst to allow the automated, low-reject production of
stress-optimized and fully consolidated organic sheets, which
can be directly reshaped, functionalized and trimmed.
The facility is safe and robust, using infrared beams as its
source of heat to weld the individual layers together. This in-
dependent system requires no extra equipment such as robots
and can be used for a large number of applications, thanks
to its variable, large-surface consolidation section. It therefore
enables the combination of carbon tapes or glass-fi ber tapes
with a wide range of matrix materials.
The facility was developed under the project “E-Profi t
– Energy-Effi cient Production of Functionally Integrated Fiber-
Reinforced Thermoplastics“ in close cooperation with
the Institute’s industrial partners.
The research and development project was funded by the
Federal Ministry of Education and Research within the Frame-
work Concept “Research for the Production of Tomorrow“
and managed by the Project Management Agency Karlsruhe
(PTKA).
Adaptive manufacturing techniques to produce pipes
from fi ber-reinforced thermoplastics
Pipe winding facilities in the oil and gas industry – used for
pipelines and pressure tanks – are not designed for mass series
production: every pipe is a unique, one-of-a-kind piece, which
is why process control systems are highly complex operations.
The laser which is used to melt down the matrix material must
deliver a precisely defi ned amount of energy into the process-
ing zone at a precisely defi ned moment, while the system and
the material are in a state of constant motion throughout the
process. This means that huge amounts of process control
data must be calculated and transmitted in real time to allow
the winding process to continue without disruptions. This is
the only way to ensure that the temperature is neither too hot
which would cause overheating in the system or in the mate-
rial nor too cold which could prevent the matrix system from
fully melting down. It is for facilities designed to manufacture
these kinds of pipes and other wound components from fi ber-
reinforced thermoplastics that the Fraunhofer IPT alongside
the other members of the EU research project “ambliFiber“,
four other research institutes and nine international industrial
partners is developing a fl exible yet highly reliable controlling
concept.
49
For this purpose, a simulation software examines the thermal
conditions in the process zone of the machine and establishes
how much thermal energy must be supplied for the winding
operation. Based on a data analysis, the control system can
adjust the input of the heat source. A process of continuous
monitoring of the winding process makes sure that the
production system can approach its maximum process speed.
Online quality controls are linked with the control system, sup-
plying it with direct feedback data about the process and the
status of tool and component. This guarantees that all process
potentials are exploited without any risk for the component
quality, but it requires the interlinking of all system and
software components into a single network through interfaces
and data processing. The data are continuously structured and
imported into databases where they are sorted and evaluated
on the basis of suitable analytical strategies.
Only a rigorous networking of software for process simula-
tions, control systems and process monitoring operations
makes it possible to implement adaptive control strategies in
industrial production lines. Such control strategies are ideally
informed by existing skills and knowledge in this fi eld, paving
the way for highly fl exible manufacturing processes.
Aachen Center for Integrative Lightweight Production
AZL
Only an integrated approach can create the conditions that are
required for an economically viable realization of lightweight
engineering strategies which use fi ber-reinforced plastics and
related multi-material systems. There is a virtually unlimited
number of ways in which different materials can be combined,
and the interactions between each of these materials and the
component design, the production processes and the compo-
nents of machines and facilities are highly complex. This is why
optimized production processes need to be based on closely
interlinked networks of material science, process technology
and production technology.
In its capacity as a partner of the Aachen Center for Integra-
tive Lightweight Production AZL, the Fraunhofer IPT has access
to the comprehensive skills and competences – covering every
section of the value-adding chain – that can be found on
the Melaten Campus of the RWTH Aachen University. This
concentration of such broad lightweight engineering skills
and experience in a single place – particularly when added to
the more general production technology know-how that can
be found at Aachen – is one-of-a-kind and an outstanding
“unique selling point“.
The AZL aims to transfer its lightweight engineering research
results into large-series production lines, implementing its
innovative process chains through the close interdisciplinary
cooperation between material scientists and production
technology experts. Its research is closely coordinated with
the lightweight engineering activities of the RWTH Aachen.
University Companies still have the opportunity of joining the
network.
More details: www.azl.rwth-aachen.de
50
51
TOOL AND DIE MAKING
The business unit “Tool and die making” of the Fraunhofer
IPT provides companies, suppliers and customers from the
tool-and-die-making industry with integrated solutions,
enabling them to meet the highly diversifi ed challenges in this
segment of the industrial economy. We cooperate closely with
the Laboratory for Machine Tools and Production Engineering
WZL of the RWTH Aachen University, the WBA Tool Making
Academy Aachen and the Aachen Center for Additive Manu-
facturing ACAM in order to provide our clients and customers
with the widest possible range of consultancy, research and
development services.
The international colloquium on “Tool and Die Making for
the Future” is generally considered as the most important
event on the industry’s calendar. The conference provides
companies with compact and practical recommendations of
how to survive on the highly competitive global market. In the
annual competition “Excellence in Production” – hosted and
organized by the Fraunhofer IPT and the WZL – a jury featur-
ing members from the worlds of business, science and politics
assesses tool manufacturers across Germany to award a
special prize to the “Toolmaker of the Year”. This competition
always attracts a lot of interest within the industry but also
from the national media.
Our services
• Individual consultancy projects
– Technology selection, use and optimization
– Cost reductions by shortened process chains
– Reduction of throughput times
– Increase of service life for tools and molds
– Surface processing and fi nishing
– Evaluation of the technological performance and process
chain design
• Research projects
• Training and education
• Tool-making performance indicator database, benchmark
projects and studies
Contact
Moritz Wollbrink M.Sc.
Phone +49 241 8904-231
52
Hybrid laser processing center for the automated repair
of injection molds
Injection molds for plastic components are often provided
with fi nely structured surfaces that must be manually repaired
and re-applied – either because these structures have worn
through repeated use or because handling errors have caused
damage. These repairs require time and costs, which is why
the Fraunhofer IPT, the Institute for Optical Systems of the
Technical University of Konstanz and four industrial partners
have, in their search for an easier, less costly and automated
method of repairing damaged injection molds, established a
hybrid laser processing center for their “ToolRep” research
project. The project aims to design the fi rst ever integrated
process chain for tool repairs in an automated, laser-based
facility. The combination of two individual processes in a
single facility which is controlled through inline measuring
technology provides end users with signifi cant competitive
advantages through shorter set-up times and a more effi cient
use of existing space.
The partners started their project by defi ning the requirements
of the overall system and by developing measuring and control
technology instruments as well as process monitoring and pro-
cess control systems. A dedicated software plans and controls
the movements of the laser tool, while a digital texture synthe-
sis helps the operator to confi gure the processes. In a machine
demonstrator, which is based on an existing technical concept,
the components are jointly tested. It is the idea of the project
to provide manufacturers and users of injection molds with an
integrated solution for quick and comprehensive repairs.
The collaborative research project “ToolRep” receives funds
from the Federal Ministry of Education and Research (Contract
Number: 02P14A032) in the program “Research for the
Production of Tomorrow” in the area a “Production Facilities
for Growth Markets – Intelligent, Easy and Effi cient”.
Industrial robots use cost-effi cient laser systems to apply
textures to large and complex moulding tools
Laser beams are very good at structuring complex and large-
surface moulds for plastic injection moulding applications such
as components for car interiors. Facilities, however, which are
capable of producing such large moulds are generally very
expensive and can easily cost more than one million Euro.
This is why the Fraunhofer IPT – together with four industrial
partners – is conducting the “RoboTex” research project with
the objective of developing a robot system that would only
cost approx. 20 percent as much.
For this purpose, the partners are using – in contrast to the
other, far more expensive solutions – a low-cost industrial
robot for the laser structuring of large surfaces. By dispens-
ing with any additional cost-intensive and labour-intensive
technology, they aim to produce a robust and cost-effective
large-scale laser system that will also be more ecological than
conventional systems and provide the industrial designers
with a wider range of options.
The system-immanent inaccuracies of the robot will be
compensated through a new, intelligent method: the laser
applies certain markers on the workpiece surface that serve
as orientation points for the subsequent step of applying
the actual texture. The robot uses a camera that can identify
both the markers and the component edges to position the
laser within the known range of permissible variation. The
integrated software will calculate and correct any deviations
on the basis of the laser’s processing data.
In every new processing step, the laser will automatically
overwrite the previously applied markers.
The “RoboTex” project receives funds from the European
Regional Development Fund (ERDF) 2014-2020
(Contract Number: ERDF-0800314).
53
Excellence in Production: Phoenix Contact wins award
as “Toolmaker of the Year 2016“
The tool construction department of Phoenix Contact has won
the main award of the competition “Excellence in Production”
and was crowned as the “Toolmaker of the Year 2016”.
Phoenix Contact also won the top prize in the category
“Internal Toolmaker With More Than 50 Employees”.
The category “Internal Toolmaker With Less Than 50 Employ-
ees” was won by Harting Applied Technologies GmbH from
Espelkamp in Eastern-Westphalia-Lippe, while the top prize
in the category “External Toolmaker With Less Than 50 Em-
ployees” went to Schülken Form GmbH from Waltershausen
near Gotha. WEBO Werkzeugbau Oberschwaben GmbH from
Amtzell in the Allgäu region was named as the best “External
Toolmaker With More Than 50 Employees”.
Assisted by a jury of experts, the Fraunhofer IPT and the WZL
of the RWTH Aachen University had identifi ed the best tool
and die manufacturers in four categories, having performed a
comprehensive comparative survey and having made on-site
visits. The ten-member jury – which featured experts from
the fi elds of business, science and politics – then picked the
twelve fi nalists, the winners in the four categories and the
overall champion. 279 tool and die making companies had
participated in the competition.
2016 was already the 13th edition of the “Excellence in
Production” contest. On the day after the award ceremony,
selected companies presented their corporate strategies at the
16th International Colloquium “Tool and Die Making for the
Future” at the Quellenhof in Aachen.
Toolmaking studies from WZL and Fraunhofer IPT
The WBA is a spin-off of the former business unit “aachener
werkzeug- und formenbau”, a joint venture of the WZL
Laboratory of Machine Tools and Production Engineering at
the RWTH Aachen University and the Fraunhofer IPT, which
is much in demand as a contact for the global tool and die
making industry. Since 1995, the two production technology
institutes have been coordinating their know-how and their
activities in this area. The WBA was established in 2010
and gradually extended to network with leading companies
from the tool and die making industry in many research and
industrial development projects.
Research and development activities are complemented by
studies of many kinds that also provide insights into current
market trends and the latest technical developments. Many of
these studies have been compiled with the assistance of the
Fraunhofer IPT and are freely accessible under this link:
http://werkzeugbau-akademie.de/angebot/downloads/
54
55
OPTICS
The Fraunhofer IPT is concentrating its skills in the making and
the evaluation of complex optical components and systems
in its business unit “Optics” which covers all stages of optics
manufacturing and its value-adding chain – from simulation
and tool design to the assembly and the fi nal qualifi cation of
the overall system.
Through a close coordination of activities in different techno-
logical fi elds, we develop customized solutions that match the
exact requirements of our clients. We always aim to expand
the limitations of complex manufacturing processes and to
allow our clients to benefi t from the latest technologies even
if innovative technologies have never before been used in an
industrial production line.
In addition to the customization of sophisticated process
technology, we also analyze and exploit the interactions
between individual manufacturing steps in the context of
digitalized process chains for optical systems. We constantly
strive to narrow down the ranges of permissible variation
inside which – at the very frontier of what modern physics is
capable of delivering – industrial production lines can reliably
operate. Businesses can easily fi nd themselves caught between
the need to innovate, quality targets and cost pressures. We
help our partners to navigate safely between these often con-
fl icting demands, allowing client businesses from a wide range
of industries – car manufacturing, lighting, sensor technology
and optoelectronics, laser systems and applications, security,
medical technology and visual aids – to make the right deci-
sions.
Our services
• Tools and mold inserts alongside coating systems
for replicating optics
• Process and material development for direct optics manufac-
ture
• Software for ultra-precision manufacture of complex geom-
etries
• Automated assembly of optical systems
• Metrological characterization of the components produced
using customized sensor and measuring
Contact
Dipl.-Ing. Reik Krappig
Phone +49 241 8904-327
56
Precision molding of infrared optics is designed
to penetrate new markets
The use of infrared optics in genetic engineering technology
is, for the time being, confi ned to high-end devices, because
such optics are rather expensive to make, their production
involving polishing or machining by monocrystalline diamonds.
This is why the Fraunhofer IPT is conducting a thorough
research into the precision molding of optics from chalco-
genide glass, starting with the question how the required
high-precision aluminium-alloy molds are produced through
machining with monocrystalline diamonds.
Additionally, the VIP (validation of innovation potential)
research project “Mass-Series Production of Infrared Optics
Through Precision Molding – MIRO”, which receives funds
from the Federal Ministry of Education and Research, has
developed anti-wear protection coatings that can lengthen
the service lives of the tools and dies. The processes can be
designed with a high degree of accuracy, thanks to a simula-
tion model for the forming process of chalcogenide glass.
All required process parameters can be defi ned before the
fi rst actual pressing, signifi cantly reducing both the process
development costs and the number of rejects on the produc-
tion line.
Robust optical elements made from glass for LED
lighting fi xtures
The growing number of LEDs will also increase the future
demand for complex ancillary lenses that are used to direct
the light into a certain direction. While many tried and tested
(as well as cost-effi cient) production processes have been
developed for LED plastic optics, it is still relatively expensive
to manufacture glass optics for high end applications. Non-
isothermal molding, in contrast to conventional grinding and
polishing technologies, can be used to produce glass optics
and even micro-structured surfaces with a wide range of
different optical functions.
The EU-funded research project CENTiMO (Contract Number:
FP7-SME-606105) aims to increase the dimensional accuracy
of optics that are not manufactured in a non-isothermal
molding process, making use of molding tools made from
new ceramic materials with extra-long service lives, but also of
customized manufacturing processes. The project furthermore
aims to produce glass optics with diameters of only a few
millimeters. Various promising strategies of using commercially
available fl at glass to produce several individual optics in a
single process step have already been developed. This can
serve to improve the cost-effectiveness of the technology and
will help to open up a market of new potential applications.
Longer service lives for forming tools thanks to new
protective coating
Until recently, the biggest drawback of the precision molding
technology has been the short service life of the forming tools,
whose surfaces wear quickly due to the contact between
workpiece and heated glass. But now, a new protective
coating has been developed (and successfully tested) in the
“Coat4Glass” project that manages to lengthen the service life
of the tools to more than 200 pressing operations by combi-
ning a platinum-iridium protective layer with an adhesive layer
made from tantalum.
During the project, the Fraunhofer IPT and its partners
subjected the wear mechanisms of the precision molding
processes to intense scrutiny. After conducting many tests
using different set-ups and methods as well as different
57
coatings and types of glass, a comparative analysis of the
test results served as the basis for the development of new
precious metal coatings. The Fraunhofer IPT used a specially
modifi ed coating facility to apply the experimental protective
layers to the tools.
Fraunhofer IPT presents compact and robust high-power
LED module
LED technology is quickly becoming the standard for lighting
systems in industrial assembly halls, in public parking lots,
sport stadiums or storage facilities. This is why the Fraunhofer
IPT and two industrial partners have developed a high-power
LED module that combines a compact shape with high
luminous intensity.
The LED module features an array of 48 optical lenses and
is – with an overall size of 150 x 150 x 50 mm – signifi cantly
smaller than other systems that pack a similar punch. With its
special light emission patterns, it can generate a peak output
of up to 10,000 Lumen.
Since LEDs – even when they concentrate their power – gener-
ate substantial amount of heat, the optics are not made from
conventional thermoplastics but from a silicon elastomer that
expands under exposure to heat. This is why the lens arrays
are manufactured in a two-component process where only the
optical lenses are made from the low-viscosity LSR material.
The mounting plate is made from aluminum and has been
inserted into the dedicated mold before the injection opera-
tion. The LSR lenses are then injected around the inserted
aluminium plate. Using the LSR material only for the functional
optical surfaces reduces the costs of producing the highly
effi cient lighting module.
Higher quality and fewer rejects for the production
of micro-lens systems
Ever higher resolutions of camera chips and screens are
increasing the demand for high-performance micro-optics and
sensor-assisted assembly processes. On the “Optatec” trade
fair, the Fraunhofer IPT showed how an “Arburg Allrounder
170 S” injection molding machine can manufacture top-
quality micro-lenses with diameters of only two millimeters
using production processes that are suitable for mass-series
manufacturing environments. It was also demonstrated how
intelligent, active assembly processes can be introduced to
compensate for manufacturing tolerances, increasing the
overall product quality.
In the research project “HiTecMass – Effi cient Mass Production
of Micro-Optical High-Technology Modules” (part of the “Lead
Market Competition for Production.NRW” state government
program for industrial innovations), the optics manufacturer
polyoptics GmbH and the Fraunhofer IPT are exploring
technologies and processes of how to reduce the rejection
rate of production processes for micro-optical high-technology
modules down to a low single-digit percentage.
58
59
LIFE SCIENCES ENGINEERING
In the “Life Sciences Engineering” business unit the
Fraunhofer IPT researches and develops pioneering technolo-
gies for the entire range of life sciences from the pharmaceuti-
cal industry and biotechnology to medical technology. As a
production engineering research institute, we have many years
of in-house experience in production processes, manufactur-
ing techniques, metrological systems, process automation,
technology and quality management. We have been applying
this expertise effectively and profi tably in the life sciences
sector.
We assemble interdisciplinary teams comprising engineering,
biology and medical experts, who develop customized
concepts and technical solutions for the entire process of
product development and support our customers through
the entire process, from the very beginning of the preliminary
research stage through market orientation and ultimately to
certifi cation. Our well established network provides us with ac-
cess to the know-how already acquired by additional scientifi c
facilities in Germany and in the USA: We have particularly
close links with the WZL of the RWTH Aachen University, the
Fraunhofer CMI and Boston University.
Our services
• Production technologies for medical engineering
• Medical and molecular diagnostics
• Technical solutions for laboratory and biotechnology
• Technical solutions for cultivation and differentiation
of stem cells
• Technology, data and quality management
Contact
Jelena Ochs M. Sc.
Phone +49 241 8904-571
60
Robot-assisted stem cell production for regenerative
therapies
Mesenchymal stem cells can be differentiated into a wide
range of cell and tissue types. This is why they offer new
perspectives for the development of personalized, regenerative
therapies against many diseases. In close cooperation with the
National University of Ireland, the Fraunhofer IPT has started
the EU research project “AUTOSTEM” which is designed to
develop a robot-assisted technique for the automated produc-
tion of mesenchymal stem cells. In contrast to (controversial)
embryonic stem cells, mesenchymal stem cells can be
produced from the tissue of adult humans, for example their
bone marrow or fat tissue, and can be propagated at will. This
creates new opportunities for the development of regenerative
therapies against a wide range of illnesses. Until recently,
however, the isolation and propagation of mesenchymal stem
cells for research purposes and clinical studies required a lot of
time-consuming, manual laboratory work.
This is why the project aims to develop a robot-assisted cell
production facility which will reduce the contamination risks
and produce huge amounts of cells in a closed and sterile
environment.
The project has received funds with a total volume of 6 million
euro from the EU-research program Horizon 2020.
Fully artefact-free aneurysm clip made from
fi ber-reinforced plastic
The treatment of locally dilated blood vessels inside the skull
with so-called aneurysm clips is part of routine neurosurgery
procedure. Surgeons place a clip around the neck of the
aneurysm to stop or prevent a potentially fatal cerebral haem-
orrhage. Conventional clips are made from metal (titanium,
e.g.) and cause problems for the MRT imaging system by
creating so-called artefacts. These artefacts make it harder to
analyze the surrounding tissue and to diagnose aneurysms.
This is why post-operative treatments are still based on
invasive (catheter) examinations or on radiation solutions (CT).
Under the SME Innovation project “Producing Fully Artefact-
Free Aneurysm Clips From Fiber-Reinforced Plastics (MR
Clips)”, the Fraunhofer IPT – in close cooperation with three
industrial partners and the Clinic for Neurosurgery of the
Saarland University Hospital – has developed a clip made from
fi ber-reinforced plastic that allows an artefact-free representa-
tion of the brain while meeting all mechanical requirements.
Until now, the main stumbling blocks on the way to develop-
ing and manufacturing such a clip were the production of
miniaturized fi ber-reinforced profi les with suffi cient levels of
complexity in conjunction and the lack of suitable plastic com-
ponents. This is why the project – in addition to designing the
clip – also had to develop a process chain for producing the
fi ber-reinforced profi le by modifying existing micro-pultrusion
techniques.
Once the clip has been approved for use in clinical practice,
follow-up examinations of patients with aneurysms who have
been treated with such a clip will no longer require invasive
methods or potentially harmful radiation.
Award-winning interdisciplinary venture in the fi eld of
bionics
On the occasion of the bionics congress “Patents From
Nature” which was held on 21 October 2016 at Bremen, Kai
Winands and Mario Pothen from the Fraunhofer IPT together
with their research partners from the RWTH Aachen University
and the Johannes Kepler University at Linz / Austria were
awarded the “International Bionic Award” of the Schauenburg
Foundation.
The scientists received this honor in recognition of their
interdisciplinary research collaboration involving production
61
technology, computer sciences, biology and physics. The
project had been inspired by the short-horned lizard which
is capable of collecting tiny amounts of ambient water in its
scaly skin and then uses fi ne skin capillaries to fetch this water
to its mouth.
Starting in November 2012, the three-year joint venture
“BioLas.exe” applied similar structures by laser to the surfaces
of complex and free-form components that were made from
plastics and metal.
By July 2015, the follow-up project “LiNaBioFluid” had already
been started, extending the scope of the biomimetic research
from lizards to bark bugs. These bugs use falling rain to
change the colour of their backs so they can blend in better
with the trees and plants in their habitat. The EU project aims
to exploit and optimize this effect for technological surfaces.
Using ultrashort pulse lasers, hierarchical micro-structures and
nano-structures are generated through direct structuring and
self-organization. This is designed to reduce friction and wear
in the use of lubricants.
The interdisciplinary consortium of the “LiNaBioFluid” project
features seven partners from four countries. The project
receives funds from the EU-program Horizon 2020 FET Open
and will be completed in July 2018.
Micro-structures and nano-structures pave the way
to the development of human tissue replacement
Nano-structured and micro-structured surfaces are capable of
inducing the differentiation of human mesenchymal stem cells
(hMSC) into specifi c tissue cells. Industrial methods – such as
laser structuring and diamond machining that have been ana-
lyzed and further developed by the Fraunhofer IPT for many
years – can serve to manufacture such surfaces on a large
scale, quickly and at low prices. This means that the industrial
production of tissue-specifi c cell replacements from hMSCs
is coming a huge step closer – we are entering unexplored
territory of biomedical stem cell research.
Laser structuring is capable of applying nano-structures to the
surfaces of virtually any free-formed component. For example,
a grooved profi le was added to tissue in petri dishes for the
purpose of muscle cell differentiation in order to induce the
expression of muscle-specifi c genes in hMSCs. By contrast,
very small groove structures can be used for the differentiation
into neural cells. The method of diamond machining was
selected to apply a structure featuring parallel micro-grooves
and a defi ned topography in the nanometer dimension to
a master tool. In a reel-to-reel process, the topography can
be transferred to a coated fi lm substrate in a continuous
embossing process before, in the next processing step, it is
shaped into synthetic biomaterials such as silicon or (in future)
collagen.
The scientists from our in-house biological laboratory have
already demonstrated that these grooved topographies that
have been represented in polydimethylsiloxane trigger the
neural differentiation of hMSCs. The cells express neural mark-
ers such as neurofi lament, b-tubulin III and vinculin to signify
focal adhesion. The target topography survives even after the
cells have been cultivated for several weeks.
62
63
OUR COMPETENCIES
A centra l task of the Fraunhofer IPT is to transfer the current research direct ly into industr ia l pract ice. We
conduct appl ied research, implement our results in an industr ia l context, and provide re levant and effec-
t ive consult ing serv ices for the direct benef i t of industry, thereby contr ibut ing s ignif icant ly to the compe-
t i t iveness of companies.
The basis of the Fraunhofer IPT’s success is the widespread
expertise in all our departments. Here we focus on our
research activities and the further development of production
technologies. Therefore, we focus not only our research on
industrially applicable production technologies but also offer
many technological products and services in the areas of
process technology, production machines, production quality
and metrology, and technology management:
• In the area of Process technology, we develop new produc-
tion processes for your applications and optimize those
already existing: from process analyses of the conceptual
development and consultation up to the practical realization,
we create integrated solutions for our customers.
• We consider ourselves to be a competent and professional
partner for the development and construction of production
plant with which to individually and effi ciently manufacture
your complex products – from initial technical advice to fi nal
implementation.
• The highest possible levels of quality, resulting in cor-
respondingly high levels of effi ciency of structure and work-
fl ow organization – this is, in the view of the Fraunhofer IPT,
the key to competitiveness and innovative strength. The aim
of the Fraunhofer IPT is to support its customers by imple-
menting excellent results of applied research for a head start.
We design and industrialize processes through effective
measuring technology and an entrepreneurial understanding
of quality.
• Sophisticated technology management is a signifi cant factor
in the success of technology oriented companies. Companies
which remain resolutely customer-focused throughout the
development, deployment and substitution phases, can build
and maintain a competitive edge. We advise our customers
in all disciplines of technology management – from the
conceptual design to the elaboration of strategies, processes
and methods for tailor-made technology management.
For the latest information about the expertise in our departments, go to our web page
www.ipt.fraunhofer.de/competencies
64
Non-Conventional Manufacturing Processes
and Technology Integration
The department “Non-Conventional Manufacturing Processes
and Technology Integration” develops new technologies to
complement or substitute existing value-adding chains, which
comprise include electro-erosive processes such as EDM and
ECM, laser technologies and high-pressure water jet abrasion.
We also integrate production technology into existing process
chains, starting with an analysis and assessment of the existing
chains, then adjusting or re-designing them and fi nally integrat-
ing new technologies into customer systems. Further, we
develop CAM modules for various processes, which also guar-
antee the industry transfer of our process knowledge . For fi elds
such as tribology, mold construction and bionics, we offer laser
beam structuring services for the application of high-precision
3D structures. We develop hybrid technologies for high-strength
and hard-brittle materials that enable a complete machining of
complex-shaped components . Electro-erosive abrasion allows a
rapid, accurate and safe production of complex geometries for
applications in turbomachine construction, medical technology
or tool and die making. The technology of high-pressure water
jet abrasion can be used in preparation for the processing of
materials that are diffi cult to machine or highly sensitive.
Our services
• Laser technologies (structuring, deposition welding,
hardening, surface treatment)
• Wire spark erosion and Electrochemical machining
• Multi-axial water jet abrasion and cutting
• Horizontal process chains for the production of single parts
and small series
• CAM modules and CAx-based process chain design
• Analysis and optimization of NC programs
• Integration of new production technology into existing
process chains
Dr.-Ing. Kristian Arntz
Phone +49 241 8904-121
High Performance Cutting
The department for “High-Performance Machining” develops
machining technologies and integrates them into practical
solutions for industrial environments, concentrating on
simultaneous multi-axial milling operations and the turning
of geometrically complex components that are made from
super-alloys, high-strength steel, lightweight and composite
materials as well as customized production materials.
Typical applications include components for turbo engine
manufacturing, the aerospace industry, tool and die making
and medical technology.
An integrated management of research and development
projects requires comprehensive technological knowledge,
skills and experience with a wide range of systems and
sophisticated equipment – all of which can be found at
the Fraunhofer IPT, which is we can provide our clients and
partners with unrivalled levels of assistance in fundamental
research, the development and optimization of processes as
well as the production of prototypes.
Our services
• Fundamental research and modelling
• Machining analyses and assessments
• Process planning and optimization
• CAM planning and NC optimization
• Consultancy and production of prototypes
Dr.-Ing. Florian Degen
Phone +49 241 8904-289
65
Fine Machining and Optics
The department for “Fine machining and optics” develops
production and processing technologies for precision
components, based on a profound understanding of the
fundamental principles involved and with the objective of
addressing actual and highly specifi c requirements of industrial
environments. For these purposes, we are using the latest
engineering and software technologies. The department’s
technology portfolio includes ultra-precision grinding and
polishing processes, diamond cutting technology as well as
the molding of high-precision glass components for which we
cover the entire process chain from mold design to the mold-
ing of the fi nished products.
We also develop robot-based and machine-based grinding
and polishing technologies, aiming to replace manual opera-
tions in tool and die making as well as in the production of
components for turbomachinery with automatic machining
processes.
Our services
• Basic research and process analyses in selected technologies
• Feasibility studies and technology design
• Profi tability analyses and implementation strategies
• Production of components
Dr.-Ing. Olaf Dambon
Phone +49 241 8904-233
Precision Technology and Plastic Replication
The department for “Precision Technology and Plastic
Replication” develops customized machines and facilities for
high-precision applications. Our engineering concepts for the
assembly of optics and reel-to-reel process technology are
highly modularized. This enables us to build up customized
facilities effi ciently and to design fl exible industrial process
chains. The department is also engaged in the creation of
sensor-assisted networks that combine machine components
and machines and in the acceleration of calibration processes
for 5-axis facilities.
The department furthermore conducts research into the pro-
duction of high-precision plastic optics and structured fi lms for
applications in medical technology and other areas. Tool and
die manufacturing and roll machining complete the process
chain from feasibility studies to series production of optics and
fi lms. The department is equipped with a comprehensive array
of sophisticated equipment and has many years of experience
in diamond machining.
Our services
• Development of customized machines and facilities
• Sensor integration and signal analysis
• Characterization and optimization of machines
• Precision assembly and automation technology
• Replication of ultra-precision plastic components and
multifunctional fi lms
• Production of embossing rollers and injection molds
Dr.-Ing. Christoph Baum
Phone +49 241 8904-400
66
Production Metrology
The department for “Production Metrology” of the Fraunhofer
IPT is dedicated to the digitalization of industrial processes. We
develop measuring technology for quality assurance systems
of manufacturing companies, making use of a wide range of
sophisticated measuring systems that we offer to our clients
for contract services while continuously developing and refi n-
ing such systems in close coordination with our partners and
suppliers.
We focus our efforts on the industrialization and automation
of production and measuring processes as well as on the
digitization and networking of production systems for the
purpose of creating adaptive process control structures and
of gathering production data. Together with our clients, we
research and develop hardware and software for digitalized
production processes with a view to rendering production
systems and production processes more fl exible.
Our services
• Optical measuring technology and imaging techniques
• Optical testing and manufacturing, short-coherent inter-
ferometry, fi ber optics, biophotonics, customized measuring
systems
• Automated production and measuring technology
Production and measuring technology, process automation,
integration of sensor systems and data feedback, assembly of
fi ber-optical systems, contract measurements
• Micro-production and nano-production
3D- and interference lithography, development of resists,
structural characterization
• Digitization and networking
Networking of sensors, machines and systems, fl exible
interfaces and integrated solutions, production data acquisition
and process control
Dipl.-Phys. Niels König
Phone +49 241 8904-113
Fiber-reinforced Plastics and Laser System Technology
The department for “Fiber-Reinforced Plastics and Laser
Systems Technology” of the Fraunhofer IPT meets the grow-
ing industrial demand for automated processes to produce
high-performance materials, developing facilities for the
manufacturing of fi ber-reinforced composites as well as
technologies for their automation. Our skills and experience
in laser systems technology allow us to optimize conventional
machines and production lines – for sheet metal processing,
e.g. – by integrating laser system modules into their processes.
We concentrate our research on fi ber-reinforced lightweight
components that are made from duroplastics or thermoplastics
(FRP) for applications in car manufacturing, the aerospace
industry, the oil and gas industries as well as mechanical
engineering. Our research and development activities comprise
the design of FRP production processes and the provision
of support for the development of new products. We also
construct customized equipment with integrated laser systems
technology for combined laser-assisted machining operations
and other ways of combining laser processing with conven-
tional machining.
Using laser beams as additional instruments in conventional
machine tools widens the functional range of the equipment,
renders the production process more fl exible and shortens the
cycle times for the production of complex components.
Our services
• Development of equipment for tape and prepreg processing
• Design and production of FRP prototype components
• Integration of laser systems into production lines
• Development of systems and process technology for laser-
assisted sheet metal processing
• Development of high-power laser processes with an output of
up to 30 kW
Dipl.-Ing. Dipl.-Wirt. Ing. Henning Janssen
Phone +49 241 8904-261
67
Production Quality
Production digitization and networking trends confront
quality assurance systems with enormous challenges, but also
represent a huge optimization potential. The analysis of large
amounts of data creates a base for more stable and more
effi cient processes, risk reduction and shorter ramp-up stages.
Smart devices provide operating staff with access to context-
sensitive information – unskilled workers can, for example,
be enabled to perform component checks. Horizontally and
vertically integrated data and information pave the way for
a fl exible and effi cient operation of individual processes and
entire production facilities.
We are creating high-quality production lines for tomorrow’s
digital factories, researching and developing high-performance
tools and processes for the effi cient manufacturing of safe and
reliable products.
Our services
• Effi cient production processes
Data analytics for process optimization, quality assurance
methods for Industrie 4.0, process management, process
chain optimization, integrated economic ecological as-
sessments, machine learning for autonomous production
processes, data structures for the production
• Smart production
Application-specifi c smart device solutions, smart glasses for
assembly and logistics, assessment and optimization of smart
device concepts, networking of all digital systems
• Networked production IT
Selection of production software systems, energy- and risk-
optimized production process control systems, organization
concepts for effi cient and digitized production processes,
process chain optimization, implementation of lean produc-
tion methods
Strategic Technology Management
Companies need to be able to identify useful technologies
quickly, to develop them so they meet the needs of their
customers, to implement them and to replace them when
something better comes up. They need a systematic technol-
ogy management in order to lay down a sustainable, future-
proof technology base that exists to meet the requirements of
their customers. We help companies to analyze product and
production technologies, strategic objectives and their specifi c
operating environments.
In close coordination with our clients, we design a customized
technology management system for them that meets their
individual requirements. We also help them to analyze their
structures in order to identify their range of core compe-
tences. Customized technology strategies allow our clients to
make the right decisions and to fully exploit their potential.
Our services
• Technology management processes and organization
• Core competence analyses and development
• Technology strategies
• Technology planning/road mapping
• Technology platforms
• Technology recycling strategies
• Diversifi cation strategies
• Technology protection
• Technology change management
Dr.-Ing. Eike Permin
Phone +49 241 8904-452
Dipl.-Ing. Dipl.-Wirt. Ing. Markus Wellensiek
Phone +49 241 8904-114
68
Operative Technology Management
The growing volume of available data – in combination with
the increasingly easy access to knowledge of all kinds – has
created an over-supply of information that some people may
fi nd confusing. We identify future technologies, products,
markets, customers and competitors, creating an integrated
foundation of facts on which technological unique selling
points can be developed that distinguish our clients from their
competitor. We concentrate our search on company-specifi c
technology developments, implement individual technology
forecasting processes including any auxiliary instruments that
may be required and make use of the technological skills and
experience of our large network.
Increasing procurement requirements and the growing com-
plexity as well as diversity of the products confront companies
with signifi cant challenges. It is important to monitor the
development of the components’ costs and to assess the
offers from different suppliers on the basis of functionality
and quality. We support our client companies in the design,
the implementation and the follow-up of cost optimization
projects and identify sustainable savings potentials for their
product sourcing operation.
Our services
• Scanning, scouting and monitoring
• Technology analyses and market analyses
• Technical due diligence
• Identifi cation of new applications
• Assessment of technologies and technology chains
• Adaptive (hardware) development
• Procurement market analyses and supplier inquiries
• Cost analyses and cost optimization
Dipl.-Ing. Toni Drescher
Phone +49 241 8904-250
69
For more information on conferences, exhibitions and honors visit our website
www.ipt.fraunhofer.de/dates
END-OF-YEAR REVIEW
Fairs
• Photonics West, 13.-18.2., San Francisco/USA
• JEC, 8.-10.3., Paris/F
• Light & Building, 13.-18.3., Frankfurt
• Lopec, 6.-7.4., München
• Hannover Messe, 25.-29.4., Hannover
• Control, 26.-29.4., Stuttgart
• AsiaBlech, 11.-13.5., Shanghai/CN
• ILA, 1.-4.6., Berlin
• Optatec, 7.-9.6., Frankfurt
• Aachen 2025, 23.-24.9., Aachen
• Wetzlarer Herbsttagung, 27.-28.9., Wetzlar
• Surface, 4.-6.10., s’Hertogenbosch/NL
• K, 19.-26.10., Düsseldorf
• EuroBlech, 25.-29.10., Hannover
• Electronica, 7.-11.11., München
• Compamed, 14.-17.11., Düsseldorf
• Formnext, 15.-18.11., Frankfurt
• Composites Europe, 29.11.-1.12., Düsseldorf
Conferences
• Aachen Polymer Optics Days 2016, 12.-13.4., Aachen
• 3D Valley Conference 2016, 14.-15.9., Aachen
• 10th Technology and Innovation Management Conference,
28.-29.9, Aachen
• 20th Business Forum Quality, 12.-13.9., Aachen
• 14th International Colloquium “Tool and Die Making for the
Future”, 26.-27.10., Aachen
70
Doctoral Theses
Flore, J.: Optimierung der Genauigkeit fünfachsiger Werkzeug-
maschinen. Diss. RWTH Aachen, 2016
Frank, S.: Mechanismen der Nahtfehlerentstehung beim
Laserstrahlhartlöten. Diss. RWTH Aachen, 2016
Hollstegge, D.: Process-Induced Changes in Optical Properties
of Precision Molded Glass Lenses. Diss. RWTH Aachen, 2016
Koerfer, F.: Simulation und Analyse geometrischer Einfl üsse
in elektronisch durchstimmbaren Weisslicht-Interferometern.
Diss. RWTH Aachen, 2016
Liu, Y.: Mesh-based CAM solution for Laser manufacturing
and repair processes. Diss. RWTH Aachen, 2016
Permin, E.: Funktionszuverlässigkeit technischer selbstoptimie-
render Systeme zur Regelung von Produktionsprozessen. Diss.
RWTH Aachen, 2016
Schenk, F.: Hochdurchsatz-Mikroskopie von Mikrotiterplatten
auf Basis einer kontinuierlichen Objektbewegung. Diss. RWTH
Aachen, 2016
Spöcker, G.: Modular Programming of Adaptive CAx Manufac-
turing Process Chains. Diss. RWTH Aachen, 2016
Ünlü, V.: Methodenkonfi guration zur Kostenanalyse tech-
nischer Beschaffungsgüter. Diss. RWTH Aachen, 2016
Wegener, M.: Ressourceneffi ziente Gestaltung von Prozess-
ketten mit additiven Fertigungsverfahren. Diss. RWTH Aachen,
2016
Awards
International Bionic Award of the Schauenburg Foundation
Mario Pothen and Kai Winands
Best idea and exemplary interdisciplinary cooperation between
scientists and experts from the fi eld of production technology
in the bionics research project “BioLas.exe”
First place in the AC² start-up contest
of the Aachen Chamber of Commerce
Markus Große Böckmann, Martin Plutz and Philipp
Siebenkotten
oculavis GmbH
Spin off of the Fraunhofer IPT, est. in 2016
JEC Americas Innovation Award 2016
Group on “Fiber-Reinforcement Technology”
and industrial partners
Automated system for the customized processing of fi ber-
reinforced thermoplastics
Best Junior Engineer Award of the WZL Freundeskreis
Grigory Rotshteyn
Degree paper
“How to Design Arrays for the Finishing of BLISKs on the Basis
of Theoretically Determined Stability Maps“
71
PUBLICATIONS
The Fraunhofer IPT has the miss ion to convert sc ient if ic knowledge into economical ly v iable innovat ions
in the f ie ld of product ion technology. This i s why we regard sc ient if ic papers as an important instrument
to demonstrate our capacity to innovate – within the sc ient if ic community as wel l as to potent ia l c l ients
and project partners.
Recent Books
Plutz, Martin; Große Böckmann, Markus; Siebenkotten,
Philipp; Schmitt, Robert
Smart Glasses in der Produktion
Studienbericht des Fraunhofer-Instituts für Produktions-
technologie IPT
Aachen: Fraunhofer IPT, 2016
Boos, Wolfgang; Salmen, Michael; Hensen, Tobias; Johannsen,
Lars; Kelzenberg, Christoph; Schippers, Max
Tooling in Germany
Aachen: WZL Forum, 2016
ISBN: 978-3-946612-03-2
Boos, Wolfgang; Salmen, Michael; Johannsen, Lars; Hensen,
Tobias; Begovic, Advan; Wollbrink, Moritz
Tooling in China. Spritzgießwerkzeugbau
Aachen: Werkzeugmaschinenlabor, 2016
ISBN: 978-3-946612-04-9
Brecher, Christian; Baum, Christoph; Simone, Daniel de;
Meiers, Bernd; Krappig, Reik
Kunststoffkomponenten für LED-Beleuchtungs-
anwendungen
Wiesbaden: Springer Vieweg, 2016, VIII
ISBN: 978-3-658-12250-8 (online)
ISBN: 978-3-658-12249-2 (print)
Gausemeier, Jürgen; Klocke, Fritz; Dülme, Christian; Eckelt,
Daniel; Kabasci, Patrick; Kohlhuber, Martina; Schön, Nico;
Schröder, Stephan
Industrie 4.0 – Internationaler Benchmark, Zukunfts-
optionen und Handlungsempfehlungen für die
Produktionsforschung
Aachen, Paderborn: Heinz Nixdorf Institut, 2016
Patents
Comanns, Philipp; Baumgartner, Werner; Bernhardt, Frank;
Winands, Kai; Arntz, Kristian
Device for the capillary transport of liquids, use and
method for producing such a device
EP000002880314B1
Schenk, Friedrich; Brill, Nicolai; Marx, Ulrich
Method and device for microscopy imaging
DE 102014217328 : 20140829
Gutermuth, Angela
Artifi cial descemet‘s membrane
DE 102015205534 A1: 20150326
A list of all scientifi c papers that have been published by the Fraunhofer IPT in 2016 can be downloaded via the “Fraunhofer-Publica” bibliography database under the following link:
http://publica.fraunhofer.de/institute/IPT/2016
72
What happened after the fi re in the WZL machine hall?
In the night from 4 February 2016 to 5 February 2016, the
machine hall of the WZL of the RWTH Aachen University was
completely destroyed in a devastating fi re. The Fraunhofer IPT,
which closely cooperates with the WZL in many projects, only
just escaped this fi re and decided to provide the WZL with
approx. 100 m² of its own machine rooms and laboratories
for precision measurements and erosion technologies. Certain
administrative functions such as the reception of goods, the
mechanical workshop and parts of the IT infrastructure were
also accommodated on the premises of the Fraunhofer IPT.
In the immediate aftermath of the fi re, research organiza-
tions and industrial partners from around the world joined
the Fraunhofer IPT and the WZL itself in providing offers
of temporary machine rentals, measuring technology and
laboratory equipment designed to allow the WZL to restore its
functionality as soon as possible. The WZL Board of Directors
– represented by the professors Günther Schuh, Fritz Klocke,
Robert Schmitt and Christian Brecher – was extremely grateful
for this demonstration of solidarity and ultimately decided – in
the interest of the continued close cooperation between the
various groups of WZL researchers and the central in-house
workshops – in favour of six sites with a total fl oor space of
3,700 m² in immediate vicinity of those WZL buildings that
were still able to operate normally.
“Now more than ever” was the defi ant motto of the
operation to move research activities into the premises of
neighbouring institutions and to intensify the cooperation
with some of the industrial partners. Research into machining
technologies was moved to the center for milling and turning,
while activities into polishing, forming and gearing technolo-
gies had to be accommodated elsewhere. At the Bogenhalle
site, 790 m² of the available space is currently used for
research into assembly technologies and robotics.
The core research activities of the Chair of Manufacturing
Technology will be accommodated on a total fl oor space of
1600 m² in the Rotter Bruch quarter. The research facilities of
this Institute had been particularly badly affected by the fi re.
Rotter Bruch is where the machining technology, polishing and
forming activities as well as the mechanical workshop and the
training facilities of the WZL have been housed.
As early as May 2016, much of the WZL machine fl eet could
be restored through the RWTH Aachen Universities purchases
of second-hand equipment. The WZL was also provided with
temporary replacements for lost machinery by some of the
world’s leading machine tool manufacturers.This portfolio in-
cludes gearing machines, 3-axis and 5-axis machining centers,
polishing equipment, erosion facilities, measuring stations and
gearing metrology equipment.
The WZL will be fully functioning once again when the
two-day Aachener Machine Tool Colloquium starts on 18 May
2017. Participants and guests will be able to acquire fi rst-hand
impressions of the progress that has been made during on-site
visits of the Institute‘s new premises.
REFERENCES
…
INNOCLAMPCLAMP
74
Publisher
Fraunhofer Institute for Production Technology IPT
Steinbachstrasse 17
52074 Aachen
Germany
Phone +49 241 8904-0
Fax +49 241 8904-198
www.ipt.fraunhofer.de
Editorial Staff
Susanne Krause M.A.
Translation
European Translation Center Ltd, Haslemere (GB)
Layout
Heidi Peters
Guido Flüchter
Photos
Fraunhofer IPT
except
Page 21: Ralf Essers
Page 26: The Visible Earth, NASA
EDITORIAL NOTES
© Fraunhofer Institute for Production Technology IPT,
Aachen, 2017
No part of this publication may be reproduced or transmitted
in any form or by any means without prior permission by the
publishers and without identifi cation of the source. Voucher
copies are requested.
Recent Information from the Fraunhofer IPT are also available
under www.ipt.fraunhofer.de and our Social Media Channels:
75
© 2017
Fraunhofer Institute for
Production Technology IPT
Executive Director
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke
Board of Directors
Prof. Dr.-Ing. Christian Brecher
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. Fritz Klocke
Prof. Dr.-Ing. Robert Schmitt
Prof. Dr.-Ing. Dipl.-Wirt. Ing. Günther Schuh
Steinbachstrasse 17
52074 Aachen
Germany
Phone +49 241 8904-0
Fax +49 241 8904-198
www.ipt.fraunhofer.de
