Precision machines and automation technology
Fraunhofer Institute for Production Technology
The work of the "Precision and special purpose machines" department covers all activities involved in the development of precision and special purpose machines. We aim to develop high-precision special purpose machines and components to meet the specific demands of our clients. We work on the basis of their requirements, either in terms of initial machine concepts, the design and optimization of critical components or control technology and the implementation of complex control systems.
Topics covered by the department
Development of specialist machines and plant
On behalf of our clients, we carry out feasibility studies on new production processes, machines and plant and on those that have already been developed further. We do this by analyzing existing manufacturing processes and developing improvements and alternatives. In the case of new developments, we can provide solutions at whatever level of detail our clients require – from the basic concept to detailed 3D designs with working plans. We can plan processes, provide the entire mechanical and electrical design of machines and plant as well as commission control and process technology. Our services in the field of specialist machines and plant are rounded off with CE certification for the developed plant.
Replication of ultra-precise plastic components
The replication of plastic components via injection molding, injection compression molding and hot stamping processes is an economic means of manufacturing ultra-precise optics and micro-structured plastic formed parts. The Fraunhofer IPT helps its clients with the design of plastic components that are suitable for production, with the manufacture of the mold inserts and with the production of small series. Extensive knowledge about processes and plant technology as well as the development of our own tooling technology means that we can guarantee high levels of component quality and dimensional accuracy in the micrometer range.
Piezo actuators in production
We use the computer-aided design of mechanical components to develop specialized solutions that integrate piezo actuators and ultrasonics into tools and specialist machines. We develop control solutions on the basis of simulation models and modify control systems, from simple control structures to model-assisted controls. We select the right hardware for the integration of controls and mechanical technology and configure the interfaces to existing machine systems.
Machine characterization
On behalf of our clients, we identify the static and dynamic errors in their machine systems and analyze the thermal stability of their manufacturing equipment. With our wide variety of measuring system equipment, we can select the right system for machines of any size and for all levels of precision. We identify the geometrical errors in spindle systems and multi-axis systems, and characterize and optimize these systems for our clients, matching all system components to each other.
Systems for the manufacture of complex optical freeform surfaces
Any kind of freeform surface has its own special requirements in terms of surface quality, dimensional accuracy and the economic efficiency with which it should be produced. The Fraunhofer IPT therefore continuously improves machine systems for the manufacture of optical freeform surfaces. We develop fast/slow tool systems for customer-specific operations, manufacture prototypes and verify feasibility through the production of small series. Our services are rounded off by the investigation of complex freeform surfaces in terms of process feasibility as well as the manufacture and development of diamond cutting.
Biotechnology and medical technology
On the issues of biotechnology and medical technology, we work on the development and manufacture of bio-functional surfaces, bio-compatible process automation for cell and plant culture and the development of minimally invasive surgical instruments.
We provide our cell culture services across the whole range of processes - from structural development to the manufacture of surface structures in the micrometer and sub-micrometer range, the manufacture of replication tools for substrate molding to the manufacture of small series for cell biology investigations.
The greatest potential for cost-effective, high quality production processes is achieved through the advancement of product and manufacturing technologies and through process automation. We can help you with this in many ways - from a simple review and advice to the development of entire plant for the automation of highly specific biotechnology and medical technology manufacturing processes. This includes product manufacture and conventional laboratory processes, which are often characterized by a large amount of manual operations.
Diamond cutting
Ultra-precision cutting with monocrystalline diamond tools is a key technology for the manufacture of high precision optical surfaces. The high quality of diamond tools combined with ultra-precision machines and climate control technology makes it possible to manufacture workpieces with optical surface quality and structural details with sub-micrometer accuracy. Decades of expertise in the cutting of metals and plastics enable the Fraunhofer IPT to provide extensive advise to its clients, to carry out feasibility studies and manufacture prototypes and small series.
Development of precision and ultra-precision machines
A wide range of equipment, knowledge and experience is essential for the development of production machines for high precision and ultra-precision applications. We use our expertise to develop and build successful high precision machine components and system components or even entire precision machines and plant that meets our clients’ needs. A transparent design process and comprehensive documentation are as important to us as commissioning the build and the control technology on site.
Sensor integration and signal evaluation
With the help of our latest and most precise measuring techniques, we quantify our clients’ machining processes. Using the measured data, we then analyze our clients’ processes and identify ways of optimizing them and improving their efficiency. We develop customized measuring systems and integrate these into existing machine systems in order to monitor ultra-precision and specialist machine processes. With the help of modified evaluation algorithms, our clients can utilize the latest sensor technologies in their production facilities.
Precision assembly and automation technology
The focus of the work here is on the automated assembly of complex mechatronic products used in optics, micro systems technology and medical technology. Our range of competencies and technology can be applied to all the stages of automation. We analyze each step of the assembly, develop assembly and adjustment strategies and carry out assembly trials and parameter studies in order to assess the technical feasibility, and can even build prototype assembly plant.
The Fraunhofer IPT has a comprehensive range of services that it offers industrial companies involved in micro and precision assembly - from consultancy and plant design support to process investigations and the development of specific components, and ultimately to the construction and commissioning of assembly systems that have been modified to meet clients’ requirements.
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