© Jürgen Jeibmann / Fraunhofer IWS Dresden

Easy-to-integrate custom solutions –

building on cutting-edge materials and laser technology#

Fraunhofer IWS is working on parts and components that can be easily integrated into existing production environments. Our research and development activities focus on designing solutions for or with our customers that quickly make the leap from lab to industrial application. Thus, in addition to industry-compatible one-stop solutions, our portfolio includes custom solutions that are particularly easy-to-integrate.

We combine research experience, the latest scientific findings, modern plant technology and processes with systems engineering and materials and process know-how, and are also building on existing basic technologies, products, processes, etc. We equally address special requirements not yet available on the market. We develop these solutions open-system so that they can be customized for the respective application and can be integrated into existing production chains. Please contact us if you would like to learn more about how we can work together with you to develop custom solutions for your production facilities.

Reference projects#

HPCi® – joining gun connects metal and plastic within seconds

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HPCi® joining gun for joining metal and thermoplastics within seconds. Possible application: joining of a hybrid B-pillar in car body construction.
© Fraunhofer IWS Dresden
HPCi® joining gun for joining metal and thermoplastics within seconds. Possible application: joining of a hybrid B-pillar in car body construction.

The success of innovative lightweight concepts depends on stable hybrid joints. We are therefore researching multi-material designs to join metals and plastics under high loads. These require safe processes to quickly and reproducibly produce strong joints from materials with different physical properties.

With the "HeatPressCool integrative" (HPCi®) process, point-to-point joints between metal and plastics can be implemented within seconds – without adding adhesives, screws or rivets. HPCi® presses both materials together and heats the metal selectively at the joint with inductive heat. The thermoplastic melts partially and bonds firmly with the metal as soon as it solidifies.

To integrate this process into production, we have developed a special joining gun with a modular design that, for example, can be mounted on a robot arm. Possible applications include body construction in the automotive industry, the aerospace and sports equipment industry, and electronics manufacturing.

LIsec – nozzle measurement for laser metal deposition (LMD)

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The LIsec measuring system facilitates quality control in laser metal deposition processes and can be integrated into existing systems.
© gierig media/Ben Gierig
The LIsec measuring system facilitates quality control in laser metal deposition processes and can be integrated into existing systems.

Process reproducibility and the precise knowledge of relevant process parameters are key criteria for the use of additive manufacturing processes in modern industrial production. While in conventional processes – such as milling – tool calibration prior to process start is state of the art, in laser metal deposition (LMD) it is a major challenge.

The measuring system LIsec, short for "Light Section", developed at Fraunhofer IWS, is now able to solve this issue. A measuring laser scans the powder stream after it exits the nozzle. A camera records the exposed particles and passes the data to an analysis software, thereby providing the ability to calculate the three-dimensional distribution of the powder stream. Even before starting the process, all important characteristic data can thus be checked and information about the wear degree of the powder nozzle can be provided. As a result, the service life of the nozzles can be maximally extended and any process errors can be excluded in advance. This significantly increases the efficiency and reproducibility of laser metal deposition. Due to its small dimensions and a customized software interface, the LIsec measuring system can be integrated into almost all existing LMD systems.

Solutions of Fraunhofer IWS#

Cost-efficient solutions for medium-sized businesses

Material and process innovations

Industry-compatible one-stop solutions

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