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 GECKO project, scientists are developing a human corneal implant that offers a novel solution through the precise biomimetic replication of the Descemet membrane and the use of stem cells from small human skin samples. The partners are combining structuring and molding technologies to manufacture the implant. Here, the project team is responding to the global shortage of donor corneas and, for the first time, creating a scalable biological alternative to donor tissue.

The scientists in the KIMEA project are developing an AI-based system that inspects the quality of MEAs directly during production. It analyzes process and sensor data, predicts the future performance of each MEA, and weeds out weaker units at an early stage. A language model supports machine operators by providing clear recommendations. To achieve this, the team at Fraunhofer IPT is generating extensive datasets, training the models, and validating them in pilot plants and real production environments to create a flexible quality assurance system.

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 "FLITS" project lays the groundwork for a new generation of high-speed fluorescence microscopy. The goal is to drastically reduce the acquisition time for large-area fluorescence images—while maintaining high image quality.

In the CoilCladding research project, the project team is developing a new method for manufacturing bimetallic bearings that is both industrially scalable and environmentally sustainable. The process used is Express Wire Coil Cladding (EW2C), developed and patented at Fraunhofer IPT. This process builds on wire-based laser metal deposition (LMD-w) and was specifically designed for coating rotationally symmetrical components.

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.