Projects at a glance – Research and Development for Industry

In the research project ECO-iL-DRY, researchers are developing a laser hybrid dryer that can dry battery foils faster, more efficiently, and achieve higher quality than conventional methods. In addition to the laser system, the project team is developing a digital process chain to not only better control and optimize the drying process of battery foils, but also to make it more transparent. To this end, the team is linking sensors, models, data analysis, and automatic control together. Their result? An automated hybrid drying system for lithium-ion battery electrodes that can be easily adapted to different production sizes and facilitate the transition to series production.

In the SOLID project, the project partners are establishing a regional value chain for solid-state batteries (ASSB) in North Rhine-Westphalia. To this end, they are analyzing existing global value chains and deriving technologies that can be transferred to regional industry. A key development of the project is an energy-efficient mini-environment for the demanding production conditions of solid-state batteries. They are also focusing on the development of PFAS-free binders for sulfide solid-state batteries.

The "UHV.NRW" project aims to improve ultra-high vacuum technology for production processes. Sensitive materials are processed under vacuum conditions, with high vacuum and ultra-high vacuum posing complex technical requirements. The Fraunhofer IPT develops new materials and production processes, including laser welding, and researches innovative pumping concepts. A central task of the IPT is the production and testing of prototypes for vacuum chambers. An outstanding example of its application is the Einstein Telescope, which, as the largest ultra-high vacuum system, is designed to precisely measure gravitational waves from the universe.

The aim of the research project “3DHeat – Hybrid Additive Manufacturing of Molding Tools for Glass Molding” is to develop additively manufactured molding tools with contour-accurate, rapidly controllable temperature control for non-isothermal glass forming. The thermal input is precisely controlled, which reduces wear. In the event of wear, the top metal layers can be removed and additively renewed without having to replace the entire tool body. The aim is to double the service life of the tools.

The MirrorScale research project is developing a new process chain for the thermal forming of optical mirror substrates. The goal is a robust, scalable forming technique for mirrors with diameters exceeding one meter. The approach eliminates the need for grinding and polishing—paving the way for a more energy-efficient, digitally integrated manufacturing process in North Rhine-Westphalia.

With the "Kompetenzzentrum Digitaler Zwilling.NRW", Fraunhofer IPT, together with four research partners and nine associated partners from industry, business, and education, is building a state-of-the-art infrastructure. It includes a wide range of IIoT technologies, both within the real manufacturing and research environments of Fraunhofer IPT and the MTI at RWTH Aachen, as well as within a jointly networked virtual data space of cloud systems, interconnected software, and corresponding platforms.

The aim of the CompSTLar project is to digitally transform the aviation industry using an integrated physical and digital infrastructure for high-performance thermoplastic composites. Rising CO2 emissions associated with the increase in air traffic give the 15 European project partners reason to strengthen the sustainability of European aviation and contribute to the EU targets for climate neutrality by 2050.

The GEPARD research project develops an AI-based assistance system that automatically generates or adapts assembly plans, CAM data and other production documents when variants are changed. The aim is to reduce the workload of experts, secure knowledge and make industrial production both more efficient and more adaptable.

In the "HyInnoLyze2" project, Fraunhofer IPT is researching how to scale up manufacturing equipment and production processes for PEM electrolyzers. The overall project aims to optimize and automate coating and joining processes for stack components and to develop efficient operational management concepts for electrolyzers to provide secondary frequency control reserves. To this end, Fraunhofer IPT is developing scaling strategies for joining multi-layer porous transport layers (PTL) and electrode structures made of expanded metal and, together with its project partners, evaluating various resistance press welding processes.

The reliability of AI-based decisions in production is to be ensured in the research project “AIDpro”. To this end, a comprehensive solution for automated data validation and anomaly detection in process data streams is being developed.