Research activities

University of Applied Sciences: New approaches to protein conformational analysis: Capillary electrophoresis in combination with ion mobility mass spectrometry and H/D exchange coupled by an innovative glass valve (ProCEVen) produced by ultrashort pulse laser technology.

Project partner:

• AbbVie Deutschland GmbH & Co.
• TRUMPF Laser- und Systems Engineering GmbH
• FEMTOprint SA
• Institute of Chemistry; 130 Bioorganic Chemistry Aalen University of Applied Sciences
• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences

Project period: September 2022 - August 2026

Project description:

The global COVID-19 pandemic has made it more than clear: One of the main challenges facing our society in the health sector is the rapid development of new drugs and vaccines. In particular, there is a lack of effective and high-precision systems for analyzing antibody-based active substances. The interdisciplinary team has set itself the goal of significantly accelerating vaccine and drug development. The aim of the joint project ProCEVen is to develop novel analytical systems to analyze protein conformations faster, more efficiently and more precisely in the production of biopharmaceutical active ingredients. The multidimensional capillary electrophoretic protein separation is to be achieved using a new type of microfluidic glass valve manufactured with high precision using ultrashort pulse lasers. To achieve this, the technicians of direct laser ablation by simultaneous short and ultrashort pulse processing are combined with laser-induced etching for the complex processing of glass substrates.

Smart-ADD impulse project: Platform Additive Technologies

Associated institutes of higher education:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Center for Optical Technologies (ZOT) Aalen University of Applied Sciences
• Department, Institute for Materials Research (IMFAA) Aalen University of Applied Sciences
• Centre for Virtual Product Development (ZVP) Aalen University of Applied Sciences

Project period: June 2021 - May 2025

Project description:
An overarching goal of the High-Tech Strategy 2025 is to increase raw material productivity in order to decouple economic growth from resource consumption. The cross-sectional Smart-ADD impulse project (IP) aims to make a tangible contribution to this by using additive manufacturing technologies to use resources only where they are functionally required, necessary. In close cooperation with the application fields "Electrical Energy Converters (IP Smart-MAG)" and "Lightweight Construction (IP Smart-LIGHT)", a demand-oriented "Additive Technologies" platform is to be developed that includes the necessary hardware and software as well as the required, necessary materials and specifically adapted processes.

In the LAZ sub-project, a process platform for the additive manufacturing of soft magnetic materials is to be developed. The focus is on the development of suitable laser parameters and process methods for processing even brittle materials such as Fe-Al or Fe-Si through adapted thermal management, as well as the production of innovative alternating layered soft magnetic multi-material layer systems with electrically insulating separating layers with superior magnetic properties.

Further Information can be found at: SmartPro

Smart-LIGHT impulse project: Smart die casting strategies through machine learning and innovative joining processes and testing technologies for hybrid lightweight constructions

Associated institutes of higher education:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Foundry Technology Aalen (GTA) Aalen University of Applied Sciences
• Department, Institute for Materials Research (IMFAA) Aalen University of Applied Sciences
• Laboratory for non-destructive material testing (LzfP) Aalen University of Applied Sciences
• Technology Center Lightweight Construction (TZL) Aalen University of Applied Sciences

Project period: April 2022 - March 2026

Project description:
Due to the increasing importance of resource and energy efficiency, the cross-industry key technology of lightweight construction will play a decisive role for the competitiveness of German companies in the global market. Innovative joining technologies for the production of multi-material composites with a wide range of applications, e.g. in automotive and Mechanical Engineering as well as in aerospace technology, are seen as game changers.

Smart-LIGHT addresses these in three sub-projects. Sub-projects 1 and 2, in cooperation with the Smart-DATA and Smart-ADD impulse projects, deal with the development of non-destructive testing methods suitable for series production and intelligent, machine-learning-based evaluation methods for die-cast components and processes (SP1) as well as hybrid constructions (SP2). In SP3, novel joining processes for the production of hybrid components made of die-cast alloys and other metals (e.g. steel) or fiber-reinforced plastics (e.g. CFRP) are being researched. The precise surface microstructuring, which is to be generated using lasers, is of particular importance here. In addition, ageing and corrosion phenomena are to be investigated in Smart-LIGHT on model samples that are characterized by good microstructure quality and good strength properties in their unaged state.

Explorative project SmartCycle: Smart recycling solutions for future technologies

Innovative projects: Sustainability of the safety concept in high-performance wire race bearings for computer tomographs through innovative laser structuring (SustBearing)

Project partner:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Franke GmbH
• Robot Technology
• Project period: June 2022 - May 2024

Project description:

The aim of the project is to research sustainable laser-based processes for the production of large wire race bearings. The use of lasers is intended to increase the operational stability of large bearings in order to meet the growing ecological and technological demands, as the established technology using adhesive joining is reaching its limits. The objectives are multi-layered and include the AI-based identification of suitable laser processing parameters, the development of a laser process for large structures and the establishment of quality assurance measures. In addition to the technological and methodological objectives, business requirements are also to be recorded and thus cost reduction potential identified at an early stage.

DFG - New equipment for research: Accurate, flexible and modular 6-dimensional additive manufacturing platform with individual in-situ analysis (6D-AF2)

Project partner:

• Center for Optical Technologies (ZOT) Aalen University of Applied Sciences
• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences

Project period: August 2020 - December 2023

Project description:

A 6-dimensional (3 spatial and 3 angular directions) additive manufacturing platform freely accessible to research groups, research units is to be developed. Individual structuring and individual analysis of the sample should be possible during the construction phase. The project is to be implemented through the cooperation, cooperative venture, partnership, collaboration of three research groups, research units.

BMWI - Structured anodes for improved fast-charging capability and increased energy density of lithium-ion batteries (Structure-E)

Project partners:

• German Aerospace Center (DLR)
• Frauenhover Company
• Math2Market GmbH
• Porsche AG
• PreciPoint GmbH
• SGL Carbon GmbH
• Trumpf Laser GmbH
• Volkswagen AG
• Centre for Solar Energy and Hydrogen Research BW

Project duration: May 2019 - October 2022

Project description:

High-capacity electrodes with a high layer thickness are being developed to increase the energy density of lithium-ion batteries. Such electrodes exhibit poor fast-charging behavior and reduced cycle stability. The project aims to contribute to resolving this conflict of objectives. The work concentrates on the anode, as this is considered to be the limiting factor. To this end, three approaches to structuring and surface modification are being researched:

- Grading

- laser structuring

- micro-embossing

The approaches are being researched and assessed, rating them on a laboratory scale. In parallel, algorithms are being developed that make it possible to predict advantageous electrode structures and to identify the

to describe the main ageing mechanisms SEI formation and lithium plating in a coupled manner. In addition, a light microscopic process, procedure is being developed with which it is possible to follow the charging and discharging process in-situ and to validate ageing models.

InnovationCampus Mobility of the Future (ICM) Baden-Württemberg: Optimized production of soft magnetic components for e-machines by combining ADDitive and SUBtractive laser processes (ADDSUB)

Associated institutes:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Department, Institute for Beam Tools (IFSW) University of Stuttgart
• Department, Institute for Production Engineering (wbk) Karlsruhe Institute of Technology

Project period: July 2021 - December 2022

Project description:

In order to increase the soft magnetic properties by reducing remagnetization losses, additive and subtractive processes, procedures for the production of internal structures in additively manufactured stator components of a transverse flux machine are to be used in combination. One of the ways in which this is to be achieved in the project is by introducing electrically insulating, high-precision microhole structures into the soft magnetic components during the additive build-up process, between two successive layers of material, by means of a controlled ablation process using ultrashort laser pulses.

ZIM project: Development of new welding strategies for the suppression of hot cracks for finite welded joints through laser-based process-integrated temperature control and high-frequency multi-layer re-melting using scanner optics (LasAlu)

Project partner:

• LaserApplikationsZentrum Aalen University of Applied Sciences (LAZ)
• Straka 3D GmbHProject period: November 2020 - December 2022

Project description:

Age-hardenable aluminum alloys offer new lightweight construction possibilities in vehicle, housing and other constructions, as higher material-specific properties can be realized with low sheet thicknesses. The laser welding of these aluminum alloys leads to critical hot cracks, which up to now can be suppressed by the slow addition of a filler wire, which does not work reliably, especially with deep penetration welds.
The aim of the project is to develop a new highly dynamic laser welding process without filler wire in order to prevent the formation of hot cracks in sheet stack thicknesses > 1.5 mm. For this purpose, the laser beam and its movement are modulated by laser-based process-integrated temperature control (LPT) and/or high-frequency multi-layer re-melting (HMW) in such a way that the crystallization processes in the welding zone are specifically manipulated and optimized. Here, individual strategies of the new LPT/HMW process are developed for finite and endless weld seam geometries as well as for different joint geometries in order to join simple and complex components with the new flexibly adaptable laser welding process.

ZIM network project: CAM software for planar 3D laser polishing of free-form geometries (3D-LaPol)

Project partner:

• LaserApplikationsZentrum (LAZ) Aalen University of Applied Sciences
• CAM-Service GmbH

Project period: March 2020 - February 2022

Project description:

The aim of the project is to develop a software solution for offline CAM-supported programming of 3D laser scanners and 6-axis robots for individual laser-based surface processing on large-scale components with complex 3D contours. To this end, algorithms for 3D segmentation, the creation of 3D hatchings and robot path generation are being developed as part of the project. At the same time, investigations/analyses for the development of process parameters for accordingly segmented hatching operations are being developed and process limits are being trained as calculation limits in the CAM system.

ZIM network project: Hybrid laser fineblanking technology for the production of highly dynamically loaded components made of different materials (LaserFee)

Project partner:

• LaserApplikationsZentrum (LAZ) Aalen University of Applied Sciences
• RPM Rüster Technologie GmbH

Project period: January 2020 - December 2021

Project description:

The aim of this project is to develop a process, procedure for the production of highly dynamically loaded components by synthesizing fineblanking and laser technologies, so that the finished component can be produced locally in a single step. To this end, a compensation unit for non-contact, high-precision positioning and a laser-based hardening and joining process for martensitic hardenable heat-treatable steels are being developed. The development of laser-based controlled tempering strategies for the targeted hardness adjustment of the joint is a core aspect of the project

Impulse project InDiMat: Innovative joining processes and stress-appropriate design concepts for hybrid lightweight CFRP multi-material composites

Project partners:

Institutes of the institution of higher education involved:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Department, Institute for Materials Research (IMFAA) Aalen University of Applied Sciences
• Foundry Technology Aalen (GTA) Aalen University of Applied Sciences
• Technology Center Lightweight Construction (TZL) Aalen University of Applied Sciences

Project period: June 2017 - May 2021

Project description:

Lightweight construction is of outstanding importance for transportation, energy supply and industrial automation. Due to the increasing importance of resource and energy efficiency, the cross-industry key technology of lightweight construction will play an important role in Germany's future competitiveness.

Carbon fiber reinforced plastics (CFRP) are among the most promising lightweight construction materials. These are often realized as multi-material composites with a wide range of applications, e.g. in automotive, aerospace and mechanical/plant engineering. The current focus of this hybrid lightweight construction is on composites made of CFRP and light metals as well as cost-efficient process approaches.

Various solutions are to be developed for this as part of the "InDiMat" impulse project: Light metal die casting is aimed at the process-integrated creation of functional cavities in cast structures, while hybrid joining addresses high-strength, durable adhesively joined multi-material composites.

Impulse project AddFunk: Additively manufactured functional and intelligent components (parts/tools/sensors)

Project partners:

Institutes of higher education involved:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Department, Institute for Materials Research (IMFAA) Aalen University of Applied Sciences
• Center for Optical Technologies (ZOT) Aalen University of Applied Sciences
• Center for Virtual Product Development (ZVP) Aalen University of Applied Sciences

Project period: June 2017 - May 2021

Project description:

Additive manufacturing is one of the key technologies for Industry 4.0 and the Internet of Things. Customized products can be manufactured in a commercial, economical, profitable way with great design freedom, and new business models and markets can be developed. As a result, 3D printing has disruptive potential. Additive processes, procedures are already being used in individual industries to exploit the advantages of this technology and produce small and very small series in a commercial, economical, financially, cost-effective manner.

However, there are still major gaps in knowledge about the possibilities for using additive technologies in both the plastics and metal sectors. This concerns, for example, the design of the components as well as the understanding of the mechanical, physical and optical properties and the possibilities of new material combinations in the direction of customized heterogeneous materials (such as CerMets, hard metals) or optical plastics. Another key challenge is surface quality.

This is where the "AddFunK" impulse project comes in and addresses the scientific questions posed by industry: Research is being conducted into additive manufacturing with new materials such as hard metals and optical materials for intelligent sensors for cyber-physical systems. The focus is on functional integration, surface quality and microstructuring using lasers.

Explorative project SurfPlus: Release agent-free die casting using laser-structured tool surfaces (SurfPlus)

Project partner:

• LaserApplikationsZentrum (LAZ) Aalen University of Applied Sciences
• Foundry Technology Aalen (GTA) Aalen University of Applied Sciences

Project period: April 2019 - March 2020

Project description:

Lightweight construction is becoming increasingly important in terms of the use of resources and energy in order to achieve cost advantages. An important technology for this is aluminum die casting.

Release agents are still used to prevent the molten aluminum from sticking to the component. They are sprayed onto the hot tool, which increases tool wear due to high cooling rates.

The aim of this project is to investigate the extent to which release agents can be dispensed with by using laser structures permanently introduced into the tool using a USP laser ("cold processing").

Vector Foundation - MINT Innovations 2018: Laser-based 3D printing of solid-state batteries (AddBatt)

Project partner:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Department, Institute for Materials Research (IMFAA) Aalen University of Applied Sciences
• Project period: December 2018 - January 2021

Project description:

In the search for accumulators with higher energy density and safety, solid-state batteries are considered promising candidates for the future. In addition to the development of suitable materials, suitable production technologies are of central importance. The "AddBatt" project aims to research the fundamental feasibility of laser-based 3D printing of such batteries. This approach is primarily intended to improve the interface properties, i.e. conductivity and mechanical stability between the solid separator and solid cathode as well as within the cathode - and thus contribute to solving a fundamental problem. In addition, 3D laser sintering offers the potential to produce batteries with flexible geometries - even in small quantities - in order to realize specific installation space requirements, e.g. for actuators in Industry 4.0 applications, or even completely printed components including batteries, e.g. for microelectromechanical systems or medicine implants.

ZIM network project: Development of innovative multi-channel rotary feedthroughs with LMD coatings for demanding applications (LMD-DrehDuFü)

Project partner:

• LaserApplikationsZentrum (LAZ) Aalen University of Applied Sciences
• Christian Maier GmbH & Co. KG
• Project period: April 2019 - Dec 2020

Project description:

The aim of the project is to develop a new innovative and very compact multi-channel rotary feedthrough for applications with installation space restrictions. The innovative short design, made possible in turn by a new innovative sliding disc seal, allows more channels to be implemented over the length. The whole thing is much easier to install and higher speeds are also possible. However, this can only be achieved by developing a new, efficient, profitable, financially, cost-effective process, procedure for coating rotary union seals with functional surfaces. The process, procedure is to be based on LMD coating and functionalized through UKPL processing.

BW foundation: Additively manufactured soft magnetic components made of layered structures for efficient electric motors (AddLAS)

Project partner:

• LaserApplicationCenter Aalen University of Applied Sciences (LAZ)
• Department, Institute for Materials Research Aalen University of Applied Sciences (IMFAA)
• Project period: May 2017 - April 2020

Project description:

Efficient electric motors require soft magnetic materials with highest induction and lowest losses. For high-speed traction motors in electric vehicles, however, today's magnetic materials quickly reach their limits due to their losses. Functionally better suited materials with higher specific electrical resistance are not used due to their difficult processability. This is where innovative manufacturing processes such as powder bed-based (selective) laser melting (SLM - 3D printing) offer a real opportunity to produce soft magnets with optimized properties while simultaneously exploiting component structures directly into tailor-made components for efficient electric motors. In the "AddLAS" project, an automated process chamber is being set up as a prototype device based on a concept developed in-house. In the future, it should also enable the additive manufacturing of precisely fitting heterostructures from several materials. The new additively manufactured materials are being tested in initial component prototypes.

DFG - New equipment for research: Accurate, flexible and modular 6-dimensional additive manufacturing platform with individual in-situ analysis (6D-AF)

Project partner:

• Center for Optical Technologies (ZOT) Aalen University of Applied Sciences
• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Project period: June 2017 - May 2020

Project description:

A 6-dimensional (3 spatial and 3 angular directions) additive manufacturing platform freely accessible to research groups, research units is to be developed. Individual structuring and individual analysis of the sample should be possible during the construction phase. The project is to be implemented through the cooperation, cooperative venture, partnership, collaboration of three research groups, research units.

ZIM network project: Development of a diamond tool in the form of an end mill with innovative chip forming and chip guiding geometry for ductile and lubricating materials, as well as a simulation tool for process optimization during development (DIATOOLS)

Project partner:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Zecha Hartmetall-Werkzeugfabrikation GmbH
• Project period: June 2017 - October 2019

Project description:

The aim of this development is to develop a new efficient and economical cutting tool in the form of an end mill with customized diamond cutting geometry for dry cutting of ductile materials. Furthermore, the development should lead to the creation of a simulation tool that can be used to quickly and efficiently simulate tools with novel geometries and test their functionality. The new tool should be particularly suitable for the dry machining of difficult-to-machine, ductile and lubricating materials such as lead-free copper alloys or soft aluminum alloys.

ZIM project partnership: Flexible, energy-efficient automation solution for the production of multi-variant 3D joints for dynamically, thermally and corrosively stressed components using a novel process, procedure of high-temperature capillary gap brazing with laser (enAbLe)

Project partner:

• LaserApplikationsZentrum (LAZ) Aalen University of Applied Sciences
• conntronic process and automation technology GmbH
• Project period: August 2017 - July 2019

Project description:

The desired automation solution for HTKS soldering is based on the novel approach of heat input using lasers. Laser processing enables locally highly restricted heat-affected zones in the workpiece, in which the non-contact beam guidance enables programmable, planar heat input directly at the soldering point. This minimizes distortion compared to other thermal processes, eliminating the need for time-consuming reworking or a special tool as an inductor (tool-free processing). This means that the position or size of the surface to be heated can be adjusted flexibly and quickly, especially for components with many variants.
surface to be heated can be set flexibly and quickly with adapted beam guidance without tools and therefore without changing the tool. Furthermore, different assemblies can be soldered in a flexible fixture using laser technology. HTKS soldering with the laser beam therefore enables small and medium-sized companies in particular to gain access to this production process, as the new automated system technology can be used quickly and easily (comparable to a CNC machining center) for the production of a wide variety of products down to the smallest quantities. High costs for tools (e.g. inductors) or heat generation
(furnace) are eliminated with the new process, procedure.

ZIM project partnership: Development of a complete system for laser polishing of aluminum die-cast parts with online camera analysis and control

Project partner:

• LaserApplicationCenter Aalen University of Applied Sciences
• hema electronic GmbH
• F.Scholz GmbH

Project period: March 2015 - February 2017

Project description:

The aim of the project is the development of a complete system for laser polishing of aluminum surfaces, preferably of industrial die-cast parts, with simultaneous camera-based process monitoring and quality assurance. In contrast to known laser polishing strategies, a cw high-power laser is to be used with the aim of achieving high surface rates. New approaches to polishing strategies and parameter combinations need to be developed for this purpose. The combination of aluminum and laser surface treatment results in completely new requirements for a camera system, as, for example, the heat radiation of the solidifying AL has not been visible up to now. The data supplied by the camera system must be correlated with the surface properties. Suitable error elimination strategies must be developed in order to eliminate sources of error that become apparent through the image analysis.

BW foundation: Development of laser processing methods for the composite material hollow sphere structures - LASERHKS

Project period: October 2010 - January 2014

Project description:

Laser processing methods were developed for the composite material metallic hollow sphere structures. Suitable simulation models were created for cutting, welding and drilling, and the experimental investigations/analyses were carried out on a CO2 laser.

InnovationCampus Mobility of the Future (ICM) Baden-Württemberg: Temperature-controlled in-situ laser heat treatment as an enabler for the processing of crack-prone, high-carbon steels in additive manufacturing (AddTemper)

Project partner:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Department, Institute of Production Engineering (wbk) Karlsruhe Institute of Technology
• Project period: August 2024 - December 2024

Invest BW: Development of a novel impurity-free electrolyte dosing station for variable battery cell types under argon environment with adapted laser joining process (ElDosBatt)

Project partner:

• LaserApplicationCenter (LAZ) Aalen University of Applied Sciences
• Laboratory for Power Electronics and Electrical Drives (LEA) Aalen University of Applied Sciences
• VAF GmbH

Project period: November 2022 - February 2025

Project description:

In current battery cell manufacturing processes, leaked or adhering lithium-ion electrolyte is carried over during dosing. The electrolyte settles on the dosing nozzles and the cell components or escapes via seals. This leads to considerable problems in the subsequent welding and sealing processes and to the emission of toxic and hazardous gases.
As part of the research project ELDosBATT, a new type of electrolyte dosing station with an adapted laser joining process is therefore to be developed. Among other things, the focus is on a high-precision pump and filling system with which the electrolyte can be dosed largely without carryover and under clean room conditions. In addition, the entire welding process chain is to be analyzed and optimized in the presence of impurities and under an argon atmosphere. These innovations are intended to significantly improve cell quality and renew their service life.

• Invest BW: Smart health monitoring of bonded joints using thin-film sensor technology (SmartConn)
• InnovationsCampus Mobility of the Future (ICM) Baden-Württemberg: Design and production of customized multi-material components for future electric machines (FutureM)
• ZIM project: Development of pyrometer-based temperature-controlled process control for powder bed-based additive manufacturing (PYRO-LPBF)
• ZIM project: Laser-based refinement of thermal spray coatings (LaVetS)
• InnovationsCampus Mobility of the Future (ICM) Baden-Württemberg: High-speed temperature acquisition for quality control of ultrashort pulse laser processing of diffusion media for fuel cells (HoT-Q)