Current Collaborative Projects

To cover the growing demand of lithium ion batteries, an increase in the productivity for cell assembly processes is necessary. The process steps of cutting, packaging and contacting are a bottleneck in the process chain and limit the output of the cell assembly process significantly. The project “HoLiB – High throughput processes for the production of lithium ion batteries” aims to increase the productivity of these process steps by the development of new technologies and the reduction of non-value-adding times within the process chain.

Regarding the cutting, a laser die cutter is developed which is able to cut electrodes within milliseconds while the electrode material is supplied continuously from a coil. A newly developed rotating stacking wheel places the electrode sheets for the packaging process. This technology replaces the pick-and-place process of a robot, as a further increase in productivity is limited for pick-and-place-processes. Laser welding is used for contacting of the electrode stack. Process quality and process speed are optimisation parameters for the welding process.

The project aims to link the different process steps as mentioned above. Therefore, the supply of the rotating stacking wheel by the laser die cutter and the electrode feed is very flexible. This leads to the reduction of buffers and waiting times and connects the process steps efficiently.
The developed technologies are realised in a prototype. An inline quality assurance is implemented in the prototype to evaluate the processes. An electrochemical analysis of fully assembled cells completes the assessment of the process.
The results of the project highly influence the productivity increase the cell assembly process of lithium ion batteries.

The German lighting industry today faces global competition and therefore demands technologies that allow lighting panels to be produced more resource and cost efficiently than before. In the "KonFutius" project, a new panel light is being developed together with six partners, in which fibre composite plastics and electronic components are integrated. Compared with conventional halogen lamps, the light not only consumes less energy, but also has up to 60 percent lower manufacturing costs.

LEMON will provide a new versatile Differential Absorption Lidar (DIAL) sensor concept for greenhouse gases and water vapour measurements from space.

During the last climate conference in Paris in December 2015, climate-warning limits have been discussed and agreed upon. In such frame, the need for a European satellite-borne observation capacity to monitor CO₂ emissions at global, European and country scales has been identified, as stated by the Copernicus report “Towards European operational observing system monitor fossil CO₂ emissions”.

New space missions are now being used (GOSAT, AIRS, IASI, …) or planned (OCO, IASI-NG, MicroCarb, MERLIN, …) for CO₂ and/or CH₄. Given the technical challenges, they are up to now mainly based on passive (high resolution spectrometers) instruments, Lidar instrument-based mission (MERLIN) is currently in development in Europe to probe methane only.

Therefore, the main goal of LEMON is to develop a versatile instrument, able to target CO₂, CH₄ and water vapour stable isotopes (H₂¹⁶O and HDO only, from now on referred to as water vapour or H₂O and HDO explicitly) with a single laser emitter.

The consortium consists of ONERA (FR), FRAUNHOFER (DE), CNRS (FR), KTH (SE), SPACETECH (DE), UiB (NO), INNOLAS (DE) and L-UP (FR). It has full expertise at Earth Observation technologies (from receiver, data acquisition, instrument control and versatile emitter) and is therefore able to fully explore, understand and validate the aforementioned advantages. The consortium is highly motivated to set-up and perform demonstrations at all instrument levels in order to showcase the project results. This will include the instrument set-up, TRL6 instrument validation, airborne demonstrations and CO₂, CH₄, H₂O isotopes measurements, as well as roadmaps and preliminary experiments towards space operation.

The LEMON total grant request to the EC is 3 374 725€ for the whole consortium and the project will be conducted within 48 months.

As part of the REMULAN joint project, Fraunhofer ILT and partners from industry are developing a laser-based coating process for the production of sol-gel-based non-stick-layers and the therefore necessary materials. The process should lead to a sustainable reduction in the use of materials, energy consumption and the associated climate-damaging emissions both in the production and application of machine components provided with non-stick-layers.

Microplastics enter our wastewater and the environment every day. Wastewater treatment plants are not able to sufficiently reduce microplastics. For this reason, the SimConDrill partners are focusing on the development of a filter which is ready for serial production and enables the filtration of particles down to 0.01mm (this equals the thickness of kitchen foil) on the basis of the patented cyclone filter. Due to its special technology, this filter is clogging and maintenance-free and not a disposable filter. Once the prototype has been built, it will be tested in a treatment plant using real wastewater.

The aim of the Interreg NWE BONE project, led by Prof. Lorenzo Morono, MERLN Insitute, Maastricht University is to research new methods for the improved treatment of bone fractures and to strengthen the performance of the North-West European economy. The four-year project started in March 2017. Eight partners from industry and research from the Netherlands, Germany, England, Ireland, France and Belgium have joined forces for this purpose.

Multiphoton polymerization (MPP) allows components to be produced with great precision – a resolution <1 μm – thanks to photo-crosslinking. Owing the high resolution, however, the build rates are so small that an economical production of components is hardly possible.

When MPP is combined with a printer based on digital light processing (DLP) for large area meshing (DLP), the build rate for a typical microfluidic device can be increased to such an extent that the process provides economical solutions for small lot production.

The project MultiPROmobil aims to study an integrated manufacturing and system technology that can produce bionically based lightweight structures efficiently in a single device with several manufacturing processes and without changing the manufacturing equipment. For this purpose, the project is researching and demonstrating a flexible and reconfigurable laser robot technology for integrated cutting, welding and metal deposition with a single processing head. This integrated process chain is intended to significantly strengthen the providers and users of the SME-dominated laser industry in NRW and, in particular, to help emerging e-mobile production in NRW remain agile on the world market.

The AMable project facilitates the uptake of additive manufacturing in companies. The partners – institutes and companies with a wealth of experience in the field of additive manufacturing – provide comprehensive knowledge and support to European SME’s, midcaps and industry. The experts accompany each idea from the start to the first prototype – each challenge receives a business case assessment to identify the potential of the idea, the suitable services to develop it and a roadmap to ramp up production for a successful market entry.

AMable implements the Industrial Dataspace principle for Additive Manufacturing which follows the paradigm of leaving the data with the owner to put each participant in full command of his intellectual property. AMable also creates a Blockchain app that enables a continuous secured documentation of creation and change across the product evolution. Data owners use this app to chain a digital fingerprint of their files for later reference or content integrity validation.

Feasibility of functional requirements is ensured by design recommendations from the experts who use the latest construction and simulation tools. For example, visualization services involve new technologies in virtual and augmented reality. Complete use cases will be stored in the AMable Digital Innovation Hub (DIH) to provide a rich variety of solutions to new projects.

The European Commission supports the AMable project which is coordinated by the Fraunhofer Institute for Laser Technology ILT in the context of the I4MS initiative.

In lighting applications as in many other segments, the trend towards lightweight construction and increased functionality is making it increasingly necessary to combine disparate materials with one another in a single product. By combining the good thermal conductivity of die-cast components with the high surface quality of injection-moulded parts, it is possible to satisfy the stringent demands of LED technology. 

The aim of this cooperation project is to develop a hybrid, amorphous thermoplastic/light-metal composite. The joining technology used for this is a quasi-full-area microscale laser structuring on the light-metal component. Through the back-moulding of the structured surface, the composite is produced during the moulding of the plastic. This high-strength material composite is resistant to changing temperatures and can also be optimised with regard to its media-proof characteristics. It can be used to produce functional, load-bearing components with decorative covering components in a single part, whereby build volume and weight as well as logistics and assembly costs can be significantly reduced through shorter process chains.

The Fraunhofer-Gesellschaft has launched a new cooperation platform to continue developing the additive manufacturing of metallic components: the lighthouse project futureAM. Six project partners, the Fraunhofer Institutes ILT, IWS, IWU, IGD and IFAM, as well as the Fraunhofer Research Institution IAPT, will secure Germany's technological lead in the field of additive manufacturing and make distributed resources more usable in a decentralized manner. One goal is to significantly accelerate 3D printing of metal parts while reducing manufacturing costs. The collaboration will create new digital process chains as well as scalable and robust AM processes. In addition, the institutes will develop corresponding system technology and automation and expand the range of processable materials.

In a joint ”Virtual Lab“, the futureAM partners will develop demonstrator components that show the practical suitability and the potential of the technologies developed. They will digitally map real systems and processes and optimize them by means of simulation tools – enabling users, for example, to make better predictions, or to detect and eliminate errors more quickly.

The project structure encompasses four fields of activity, which are intended to help secure the technological lead in AM: 1. Industry 4.0 and Digital Process Chains, 2. Scalable and Robust AM Processes, 3. Materials, and 4. System Technology and Automation. Fraunhofer ILT in Aachen, which will coordinate the lighthouse project for a period of three years, is in charge of the second field of activity. The scientists from Aachen are developing robust additive manufacturing processes as well as novel plant designs with large building spaces to increase process scalability.

A novel laser-based connection technology will be developed in which the surface of glass components can be modified by micro- and nanoscale laser structuring. Thanks to this technology, high-strength and temperature change resistant plastic-glass composites can be produced with thermoplastics and subsequent laser transmission welding or injection molding. The new joining and assembly technology significantly shortens process chains, eliminates additional materials and process steps and expands the design options for functional components.

Generative manufacturing processes have the potential to increase the flexibility of industrial production and to integrate connected customers and business partners more firmly within the production process. Additive laser or electron beam technology can be used to manufacture even very complex structures without major additional outlay. This opens the door to customized mass production. However, the production processes for parts produced using additive methods remain time consuming and expensive since the majority of the individual steps in the process are performed in isolation from one another and involve considerable manual intervention. This means that there is considerable capacity for saving time and manufacturing costs by linking various steps in the additive manufacturing process.

High-performance components are increasingly being produced through a combination of various multi- and hybrid materials. For such combinations to succeed, a suitable joining technology is needed since there are few technologies to produce a reliable joint with these new, innovative materials, especially dissimilar ones. Such materials include ceramics (e.g., SiC) as well as metals and lightweight metals (e.g., Al, Cu, Ti). With special active solders and at temperatures above 850 °C, materials with difficult-to-wet surfaces can be provided with a metallic layer in a vacuum or inert gas. However, when complete components are heated, internal tension and, thus, cracks can often occur. For this reason, LaMeta aims to develop solders of suspensions with microparticles that have a metallization temperature up to 50% lower than previous ones, and to apply them to components locally where metallization is needed. Subsequently, the suspension is selectively heated with laser radiation so that a cohesive connection with the base material is formed as a thin metallization layer. In further steps, conventional joining can be carried out at low stress.

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.