Current Collaborative Projects

The aim of the "OPV4.0" project is the production of highly efficient and durable organic solar cells, whose application potential is to be demonstrated in laminated glass. The increase in efficiency of organic photovoltaics (OPV) is achieved through the development of new additives that are added to the coating fluids. In addition, individual process steps within the production chain of a roll-to-roll (R2R) system are optimized.

The coating fluids should not only provide high efficiency in the OPV layer stack but also meet sustainability requirements (non-hazardous and non-toxic solvents), R2R processability, contact ability via inkjet processes, laser processability, and suitability for laminated glass processes.

Within the Fraunhofer ILT, the process steps for this project include various laser technologies. These include photonic drying of the coating fluids, cell separation through laser scribing, nano structuring for efficiency enhancement, and finally, the encapsulation of the OPV. The development of a flow- and temperature-optimized slot die, which is subsequently produced using additive manufacturing, is intended to enable optimal thin-film deposition.

Additionally, the digitalization potential of an R2R-OPV production in terms of Industry 4.0 and the application possibilities in laminated glass will be demonstrated. The design and integration of full-area sensors and process control will lead to digital monitoring of the individual sub-processes in series production and therefore to an increase in reproducibility. Through this project, a complete, efficiency-optimized process chain for OPV production will be provided for the first time, and the application potential of OPV in laminated glass will be demonstrated.

The ProZeF project (Project Week on Future Energy Fusion) brings together three partners to develop interdisciplinary, multimedia, and participatory educational material for project weeks in secondary schools around the Aachen region and beyond. By engaging with the topic of fusion, students develop a deeper understanding of its potential as a climate-neutral energy source. They reflect on the role of energy in society, and gain insights into how global research efforts aim to ensure sustainable energy supply. The project fosters environmental awareness and empowers students to see themselves as part of a global movement towards a sustainable future.

In the DIOHELIOS project – a project within the overarching BMBF funding programme Fusion 2040 – Research on the Way to a Fusion Power Plant – the partners are looking at various issues along the value chain of a diode laser pump module for high-energy lasers. Among other things, the project involves the development of customized, highly efficient diode laser bars, their stacking in a compact design with a high fill factor, beam shaping with optimized optical components, the supply of highly dynamic current drivers and specially adapted cooling technology. Finally, a scalable concept for high-energy pump sources will be presented and validated using laboratory demonstrators with >80 kW and up to >1 MW peak power on a characterization setup developed in the project.

DIOHELIOS is pursuing particularly innovative approaches such as wavelength-stabilized multi-junction laser bars, a mounting concept with efficient heat dissipation and the automation of processes using AI-based methods.

In the pilot project, the partners are undertaking fundamental work on laser systems, optical components, damage and destruction thresholds (LIDT) across the entire value chain. The focus is on mirrors, lenses and gratings:

• Investigation of new optical materials
• Novel manufacturing processes for optics
• New classes of optical coatings
• In-situ characterisation
• Techniques for damage reduction

Development of a holistic overall concept for laser-induced damage mechanisms

SIROCO (SImple and RObust laser source with EU supply chain and Cavity and injection-free Optical parametric oscillator for spaceborne lidar) aims to reach EU independence for high-power lasers in the eye-safe region. A solution based on wavelength conversion from a 1µm laser will be matured, ensuring EU supply chain independence for power laser emission in the 1.5-3µm range. Such breakthrough laser will build the foundation of next greenhouse gases (GHG) spaceborne sensors by Integrated Path Differential Absorption Lidar (IPDA), by which GHG of interest can be probed in the 1.6μm or 2μm eye-safe regions. To meet the stringent spectral, spatial beam, and power properties required, efficient and versatile wavelength converters such as Optical Parametric Oscillators (OPOs) pumped by mature 1μm power lasers are key enabling technologies. This is also the approach in the European Methane Remote Sensing Lidar Mission (MERLIN).

SIROCO will mature innovative critical optical space technologies to TRL6, including a hybrid fiber/bulk 1μm laser combined with a new Backward Wave OPO (BWOPO) concept. This will lead to a drastic simplification compared to the state of the art, as no optical cavity is required (higher robustness and easier integration), nor any OPO seed source (higher compactness and simplicity in wavelength control). It will increase EU competitiveness by faster integrated, less risky, more sensitive future spaceborne lidar. SIROCO will develop nonlinear crystals to ensure an EU supply chain, which are key components for various applications (general laser physics, lidar emitters, quantum applications). Their exploitation path towards future spaceborne lidar and quantum communications will be delivered through two public technical roadmaps.

The aim of the SAHEP project is to develop a cost-effective inline probe for wastewater analysis based on the functional principle of 2D-fluorescence spectroscopy. A new type of light source, either based on a single-filament plasma discharge or on UV-LEDs, offers the possibility of overcoming the current limitations of the usual UV light sources used for fluorescence spectroscopy. This light source is intended to be used to develop an inline 2D fluorescence probe that enables a new form of continuous monitoring of water treatment processes.

Components subject to severe wear and corrosion often fail due to localized surface damage. The replacement of failed components is resource-intensive and the recycling of metallic components requires energy-intensive melting processes. In addition, the increasing demand for increasingly scarce raw materials leads to economic dependence on importing countries and causes a significant environmental footprint due to the CO2 emissions generated in the manufacturing process.

At Fraunhofer ILT, an automated hybrid process chain for the sustainable repair of metallic components is being developed as part of the "PRECIRC" research project. By combining the turning process with extreme high-speed laser cladding (EHLA), a process chain is created that enables both additive manufacturing and pre- and post-processing of the components in a single clamping.

Efforts to mitigate climate change have made understanding and monitoring atmospheric physics (including wind and temperature distributions in the atmosphere) increasingly important. It is crucial to improve climate models and weather forecasts. However, there is a data gap for continuous measurements above 5 km, which is the maximum height of commercial compact wind radars and lidars. The EU-funded EULIAA project will develop a lidar array measuring autonomously the atmospheric wind and temperature from 5 km up to 50 km on a 24/7 basis over a long period (more than 1 year without maintenance) and covering a large observation area (up to 10 000 km²). The new lidar units are low priced, compact, efficient, easily transportable, and powered by wind turbines or solar panels.

EULIAA will yield novel data sets in near real-time for implementation into European databases Copernicus and GEOSS, that will fill current data-gaps and help to monitor the effects of climate change and to evaluate climate protection measures.

Once the enhanced capability developed within EULIAA has been demonstrated and validated in difficult-to-reach regions (polar, equatorial, and mountain), with a high TRL (6–8), a business plan and roadmap for a European array will be produced, involving relevant industrial, standardisation, and end-user actors.

The EULIAA project (lasting 48 months and budget of 3.2 M€) gathers 7 partners from 5 countries with experts in lidar and its subsystems, atmospheric observatories, and atmospheric data provider. It contains all the necessary disciplines to ensure the technological development, data transfer, and sustainable exploitation.

Per- and polyfluorinated alkyl substances (PFAS) have become an integral part of our daily lives. However, PFAS have long been classified as acutely harmful to both the environment and human health. Due to their persistence as so-called “forever chemicals,” they can now be found almost everywhere on Earth — in humans, animals, and ecosystems. As a result, the development of new processes and materials to replace PFAS with environmentally friendly and non-toxic alternatives is urgently needed. In the RePEEK project, the Fraunhofer Institute for Laser Technology ILT is introducing PFAS-free high-performance coatings into practical use. The key lies in producing a hybrid composite layer consisting of an additively manufactured metal layer — created using the EHLA process (extreme high-speed laser cladding) — combined with a coating made from the high-performance polymer PEEK (polyetheretherketone). At the heart of the innovation is the integration of two processes into a single hybrid step. First, a metal layer is applied to a metal component using EHLA. Immediately afterward, PEEK powder is applied to the still-hot component, where it melts and bonds directly. This approach offers several decisive advantages:

• Production of a complex coating system in a single process step
• Elimination of energy-intensive furnace treatments
• High adhesive strength through mechanical interlocking between the metal and PEEK layers

The project’s unique selling point lies in the close coupling of two processes and the deliberate use of their process-specific characteristics — such as residual heat and surface properties. By combining both steps in a single processing head, substantial added value can be achieved with minimal additional effort. Moreover, this innovation can be easily integrated into existing manufacturing systems as a drop-in solution.

The RUBIN consortium "LidarCUBE" consists of nine predominantly regional industry and research partners. The common goal is the prototype development of a lidar measuring instrument for automatic atmospheric measurements that can be used worldwide and on a mobile basis. The resulting high-tech product LidarCUBE will make it possible to carry out global atmospheric measurements in the future and will be unique worldwide.

The Fraunhofer ILT is further developing the laser technology based on alexandrite for this purpose and is preparing a technology transfer

LaserWay aims to revolutionize the manufacturing industry through high-speed laser processes. The focus is on replacing conventional manufacturing processes with high-precision laser processes that offer increased productivity. A key objective is to significantly reduce CO2 emissions in order to promote more sustainable production methods. Ultimately, LaserWay aims to offer competitive, flexible and environmentally friendly manufacturing solutions.

With 600,000 new cases annually, squamous cell carcinoma of the oral cavity is one of the most common types of cancer. Extensive tumors often affect the jawbone, which is why it is routinely resected. However, since there is no rapid section procedure for bone tissue and to ensure that the tumor is completely removed, a generous segment of the jawbone is often removed. Retrospective studies show, however, that in 45% of cases, the jawbone was not affected by the tumor.

An intraoperative measurement method could therefore help to avoid unnecessary resection of the jawbone. In combination with a high-precision laser cutting process, it would even be possible to perform minimally invasive surgical procedures in cases of slight bone involvement, thereby preserving the jawbone.

For this reason, a robotic laser surgery system is being developed for the precise resection of tumor-affected jawbones. A robotic arm performs the laser cut, while an OCT measuring beam monitors the cutting depth. The laser applicator moves along a cutting line previously calculated using preoperative CT or MRI data to cut out small bone segments. During resection, a LIBS sensor analyzes the chemical composition of the removed material to determine the distribution of tumor cells in real time. Based on this data, the target trajectory for the cut is dynamically adjusted and visualized in a VR display. The entire collaborative robotic laser surgery system will be implemented as a demonstrator and installed in an experimental operating room at the University Hospital Aachen.

In Germany, 620,000 spinal surgeries are performed annually. Out of these, 111,000 operations are specifically performed for the surgical treatment of spinal canal stenosis. This refers to bony narrowing of the spinal canal that compresses the spinal cord and nerve roots. The compression leads to pain in the back and extremities, and in severe cases, numbness and paralysis. To decompress the spinal canal, the surgeon must drill into the vertebral body under high pressure and stop the process immediately when he reaches the point of penetration into the spinal cord. In 1.5% of cases, the drilling head enters the spinal canal. This injures the spinal cord or nerve root, resulting in serious consequences for patients, such as paraplegia or bowel and bladder incontinence. Therefore, the aim of the SAVECUT project is to develop a robot-assisted laser surgery system for the safe removal of bone tissue near critical neural structures, which optically monitors the surgical laser process. Before reaching the spinal cord, the laser process stops instantly to prevent serious injury.

Detecting tumor cells in bone in surgery and removing them with high precision

BMFTR funding measure for health technologies as part of the National Decade Against Cancer (NDK) on the topic of “AI-supported precision surgery in oncology”

Motivation

Primary bone tumors primarily affect children. With a five-year survival rate of only 70 percent, the disease has a poor prognosis. The high mortality rate is also due to the fact that it is currently not possible to detect individual tumor cells in the bone during surgery in order to remove them in a targeted manner. The cells remaining in the bone lead to renewed tumor spread.

Goals and approach

Researchers are therefore developing a laser surgery system that will enable surgeons to remove tumors from the bone safely and without leaving any residue, while preserving as much healthy bone tissue as possible. It consists of a spectroscopic laser measurement system that can detect individual tumor cells and smaller tumor cell clusters in the bone during the laser surgery process. Artificial intelligence compares the spectroscopically measured tumor distribution with previously created CT images of the bone tumors and instructs a robotic assistance system to support the incision during surgery. The bone tumors are removed with high precision using a laser scalpel whose short-pulse laser radiation reaches a wavelength that is strongly absorbed by bone tissue.

Innovations and prospects

The system to be developed combines intraoperative tumor detection and high-precision laser surgery. This makes it possible to completely remove bone tumors and significantly improve the prognosis for those affected.

Using infrared spectroscopy, it is possible to classify healthy and pathologically altered tissue in histological cuts. Biochemical markers with spectral fingerprints in the mid-infrared (MIR) enable identification of tumor subtypes and specific therapy. However, classical MIR-spectroscopy requires long measurement times to achieve the necessary high-resolution images which hinders the introduction into clinical diagnostics.

The joint project »QEED« aims to develop a novel measurement method based on entangled photon pairs – the “Quantum-Enhanced Early Diagnostics”, or QEED-microscopy. Based on the physical effect of quantum interference, the measurement information is transferred from the mid-infrared to the near-infrared, allowing detection with reduced noise.

Fraunhofer ILT develops the required high-resolution spectrometers tailored to the QEED spectral range and develops efficient data processing algorithms on FPGA-based realtime electronics to recover the mid-infrared measurement information.

The QEED-microscopy is being developed as modular extension for traditional optical and fluorescence microscopes and will be evaluated in animal models as well as clinical studies.

LASHARE is the acronym of a European project involving more than 30 SMEs from across Europe, partners from industry and six of the most renowned laser research institutes.

Main objective is to share knowledge on laser-based equipment and its use addressing the whole value chain end to end. As a key success factor for European manufacturing the transfer of innovative solutions from the laboratory into industrially robust products and the dissemination of its use stands at the heart of the project.

PhotonHub Europe is a European initiative for small and medium-sized enterprises (SMEs). More than 50 research centers from the field of photonics support the use of photonic technologies in SMEs with their offerings. Along different application areas, these technologies are divided into eight platforms. They range from a focus on components such as optical fibers to semiconductor circuits with integrated photonic functions (Photonics Integrated Circuit / PIC) and laser-based application processes. The aim of PhotonHub Europe is to transfer complex technologies to companies so that they can employ this knowledge to strengthen their innovative power and improve their products. 

Das vorliegende Projekt "Roll2Sol" adressiert den Innovationswettbewerb Industrie.IN.NRW mit dem thematischen Schwerpunkt "Innovative Werkstoffe und Intelligente Produktion" in Bezug auf die Förderperiode 2021-2027 des Europäischen Fonds für regionale Entwicklung (EFRE). Mit dem Fokus auf die Produktion von großflächigen funktionalen Folien mithilfe der UV-Nanoimprint-Lithographie (NIL) im Rolle-zu-Rolle (R2R) Verfahren adressiert das Projekt "Roll2Sol" das Thema Innovative Werkstoffe und intelligente Produktion an mehreren Stellen. Mit den im Projekt hergestellten funktionalen Folien soll der Grundstein zur Erschließung neuer Anwendungsfelder solargetriebener Komponenten für die regenerative Energietechnik gelegt werden. Zum einen sollen Schutzfolien mit “Anti-Soiling”-Funktion für die bestehende Photovoltaik getestet werden, zum anderen sollen mit neuen Werkstoffen aus der Halbleitertechnik Folien mit photokatalytischer Funktion zur Erzeugung von grünem Wasserstoff erforscht werden. Beide Anwendungen sollen auf dem Potential der R2R-Technologie unter Verwendung funktionaler Werkstoffe und innovativem Strukturdesign aufsetzen und die Anwendbarkeit für die regenerative Energietechnik demonstrieren.

The increasing demand for hydrogen technologies necessitates the development of modern manufacturing processes with very high cycle rates. Currently, the PEM fuel cell (Polymer Electrolyte Membrane) is the focus of ongoing research and development. A key component of a PEM fuel cell is the bipolar plates (BPP). However, the aggressive chemical conditions in a fuel cell lead to corrosion of the metallic BPPs. To combat this corrosion and extend the lifespan of the fuel cells, coatings can be applied. At the same time, high electrical conductivity must be maintained to ensure system efficiency. Conventionally, coating is performed using chemical or physical vapor deposition in vacuum systems, which require complex equipment and incur high material costs.

In the H2GO research project, Fraunhofer ILT is developing a laser-based method that enables the creation of novel carbon-based corrosion protection layers. A precursor solution is sprayed onto the BPPs and dried. The subsequent laser treatment transforms this precursor layer into a conductive and corrosion-resistant carbon modification. Unlike established vapor deposition methods, this process occurs in ambient air and does not require a vacuum, significantly simplifying integration into a continuous manufacturing line.

By eliminating complex vacuum processes and using inexpensive, readily available materials, this method can help meet the growing market for PEM fuel cells. The research and development project underlying this report was conducted on behalf of the Federal Ministry for Digital and Transport under funding code 03B11027A.

R2MEA project aims to develop innovative processes for the Manufacturing of the 7-layer Membrane Electrode Assembly (MEA). It focuses on transforming production processes from batch or intermittent processes to continuous roll-to-roll ones. The main key points that R2MEA addresses are:

• Converting the catalyst powder production from a batch process to a continuous one.
•  Comparing different application mechanisms of catalyst layers
• Shorter drying times and dryer lengths using laser-based drying
• Roll-to-roll process for cutting MEA components such as the membranes, the subgaskets, and the gas diffusion layers.
• Roll-to-roll positioning and lamination processes to produce 7-layered MEAs.
• Designs for MEA transport containers.

In the framework of the ATIQ project (quantum computers with stored ions), the Fraunhofer ILT is working with a total of 24 other partners to develop reliable quantum computer demonstrators for complementary use cases, including quantum chemistry (reaction chemistry), finance (credit risk assessment) and applied mathematics (optimization problems).

The project is aimed to manufacture a commercial prototype based on the ion-trap technology with a total number of (initially) 40 qubits and a correspondingly high gate fidelity.

Project partners: 

Gesellschaft für Angewandte Mikro- und Optoelektronik mit beschränkter Haftung - AMO GmbH, AKKA Industry Consulting GmbH, Black Semiconductor GmbH, eleQtron GmbH, FiberBridge Photonics GmbH, Fraunhofer IOF, Infineon Technologies AG, Johannes Gutenberg-Universität Mainz (Institut für Physik), JoS QUANTUM GmbH, Leibniz Universität Hannover, LPKF Laser & Electronics AG, Parity Quantum Computing Germany GmbH, Physikalisch-Technische Bundesanstalt Braunschweig und Berlin (PTB), QUARTIQ GmbH, QUBIG GmbH, RWTH Aachen, TOPTICA Photonics AG, TU Braunschweig, University Siegen