Fraunhofer Institute for Laser Technology ILT
Fraunhofer Institute for Laser Technology ILT

Digital Twin

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Our range of services

In the process from development to delivery, a lot of information about a product is generated. The higher the number of components and processing steps, the larger the database becomes over time. At that point, it is usually difficult to grasp the relationships and influencing factors at a glance. In this context, the concept of the digital Twin plays a central role.

The digital twin comprises the virtual model of the process by collecting and analyzing the real data. Influencing factors can now be easily identified and cause-effect relationships can be revealed without intervening in the real process. The digital twin, therefore, enables users to better control complex production processes and their cause-effect relationships.

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Based on the individual requirements of the digital twin, a specific identification and classification of relevant data can be carried out. Core competencies in the field of modelling, simulation and process development can be seamlessly linked to this, so that simulation of material behavior, prediction of results of laser material processing or the technical performance of systems in the field of lasers and optics are possible. The real data resulting from the production is digitized in order to realize a continuous alignment in digital space.

We create a digital mirror image of your product.

Digital models of geometries and surface properties

  • Algorithms for the description of free-form surfaces and refractive properties
  • Closed formulation of thermal, optical and geometrical properties for optical elements
  • Algorithms for displaying the relationships between geometry, material, manufacturing process and product properties

Digital image of the virtual and real world

  • Documentation of requirements and solutions throughout the development process
  • Linking of current process data to the course of production via networking of production resources
  • Analysis and prediction of the production result based on design data and current progress data

Markets

Laser technology can solve demanding tasks in many different industries. Whether as a tool in automotive production, as measuring equipment in the environmental sector, as a diagnostic or therapeutic instrument in medical technology or as a communication medium in space technology, the laser provides multiple uses with high productivity and high efficiency.

Read up about the innovations of the Fraunhofer ILT in a few selected industries and convince yourself!

Technology Focus

 

© Fraunhofer ILT, Aachen, Germany.

Research with us!

Please do not hesitate to contact us if you have any questions about general topics! Our contact persons are happy to get in touch with you.

Kontakt

Digital Twin

Our contributions in this range of services for a digital image of your product or solution.

Contribution

  • Recording and evaluation of digital component models along the additive process chain
  • Modules for connecting machine parts on the fieldbus level to the data aggregation in the system context
  • Intelligent AM components through integration of sensors and electronics
  • Process monitoring during laser-based melting from the powder bed (LPBF) of metals
  • FEM modules for calculation of heat conduction, flow, thermomechanics in design and production
  • Real-time process monitoring with multisensor systems for laser material processing

Links and Downloads

Adams, M., Nießen, M., Maciejak, F., Kheirandish, Z., Kröger, M., Holly, C.:
Combining Bayesian optimization and advanced modeling into a workflow for first time right production of complex microstructures using laser ablation.
LASE, 2025, San Francisco, 25-31 January 2025, California, United States. Proceedings Volume 13351, Laser-based Micro- and Nanoprocessing XIX; 133510N (2025)
https://doi.org/10.1117/12.3042139

Bekemeier, S., Caldeira Rêgo, C.R., Mai, H. L., Saikia, U., Waseda, O., Apel, M., Arendt, F., Aschemann, A., Bayerlein, B., Courant, R., Dziwis, G., Fuchs, F., Giese, U., Junghanns, K., Kamal, M., Koschmieder, L., Leineweber, S., Luger, M., Lukas, M., Maas, J., Mertens, J., Mieller, B., Overmeyer, L., Pirch, N.(...):
Advancing Digital Transformation in Material Science: The Role of Workflows Within the Material Digital Initiative.
ADVANCED ENGINEERING MATERIALS, 27(8), 2402149- (2025)
https://doi.org/10.1002/adem.202402149 (Open Access)

Adams, M., Holly, C., Rauch, S., Traub, M., Hoffmann D., Haefner, C.:
Multiphysics analysis of chip and resonator designs for increased damage threshold of external cavity high-power laser diodes.
OPTICS EXPRESS 32(4), 6446-6462, (2024)
https://doi.org/10.1364/OE.503081 (Open Access)

Adams, M., Holly, C., Traub, M., Hoffmann, D., Haefner, C.:
Towards Robust Laser Diode Pump Sources for Inertial Fusion Energy - Multiphysics Modeling of Catastrophic Optical Damage.
IEEE Photonics Conference (IPC), 10-14 November 2024, Rome, Italy. 2024 IEEE Photonics Conference (IPC), (2 S.), (2024)
https://doi.org/10.1109/IPC60965.2024.10799839

Adams, M., Holly, C., Rauch, S., Traub, M., Hoffmann D.:
Evaluation of design concepts for feedback-resistant 9xx-nm high-power laser diodes.
SPIE LASE 2023 | San Francisco, California, United States | 28 January - 3 February 2023.
Proceedings Volume 12403, High-Power Diode Laser Technology XXI, 124030B, (9 S.) (2023)

https://doi.org/10.1117/12.2647171

Ünal-Saewe, T., Vedder, C., Vervoort, S., Schleifenbaum, J.-H.:
Digital Twins in the Product Life Cycle of Additively Manufactured Components. In:
Frenz, Walter: Handbook Industry 4.0. Law, Technology, Society, Springer, 491-501, (2022)
https://doi.org/10.1007/978-3-662-64448-5_25

Fischer, G., Birk, N., Luecke, T.G., Praetzsch, N.:
Detection of part geometry in Laser Powder Bed Fusion using layer-wise images.
ASTM International Conference on Additive Manufacturing (ICAM 2021),1-5 Nov 2022, Anaheim, CA, USA.
Shamsaei, Nik, Hrabe, N., Seifi, M.(Ed.): Progress in Additive Manufacturing 2021, STP1644, 86-100, (2022)
http://doi.org/10.1520/STP164420210131

Fischer, F., Birk, N., Rooney, L., Jauer, L., Schleifenbaum, J.:
Optical process monitoring in Laser Powder Bed Fusion using a recoater-based line camera.
Additive Manufacturing 47, 102218- (14 S.) (2021)
http://dx.doi.org/10.1016/j.addma.2021.102218  (Open Access)