Projects at a glance – Research and Development for Industry

HEPAD tackles overloaded short‑range logistics with an innovative heavy‑lift drone that combines lightweight construction, high‑power batteries and precise cell monitoring to achieve an exceptional payload‑to‑weight ratio. An IoT architecture enables continuous condition analysis, efficient fleet management and predictive maintenance. A demonstrator proves performance, safety and ecological benefits, creating a scalable, emission‑free transport solution for industry and urban environments.

In the “EnablingSapphire” project, the Fraunhofer Institute for Production Technology IPT and the Fraunhofer Institute for Laser Technology ILT are developing a digital manufacturing platform for producing complex components and tools made of sapphire. The goal is to create a cost-efficient, precise, and scalable process chain that integrates laser-based and conventional manufacturing processes. The platform targets applications in quantum technology, high-power and high-frequency electronics, and high-temperature glass forming, and lays the foundation for later industrial implementation.

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.

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 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.

In the PRIMAD research project, the partners are optimizing the development and production process for optical glass components. Using simulation, inline measurement technology, AI, and a digital twin, quality data is automatically collected and analyzed. This helps reduce development times, testing efforts, and scrap. Companies can bring new optical products to series production more quickly, use production facilities more efficiently, and manufacture high-quality components cost-effectively while maintaining consistent quality.

Repairable battery modules are key to sustainability, as current bonded designs hinder cell replacement and increase waste. The partners in the ModuRep project are developing modular, safely serviceable architectures with optimized interfaces and advanced balancing to extend lifespan. Prototypes, tools and analyses define safety and repairability requirements. Cell‑level replacement cuts CO₂ emissions and supports the circular economy.