FRAUNHOFER ILT
PARTNER FOR INNOVATIONS
Dr.-Ing. Damien Buchbinder, July 2014
© Fraunhofer / Cro & Hee
Stand März 2013
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
Fraunhofer Profile
!! 66 Institutes
7 Groups:
!! Information and Communication Technology
!! more than 22,000 employees
!! Life Sciences
(2012)
!! Microelectronics
!! An annual financial volume of
!1.9 billion, of which !1.6 billion is !! Light & Surfaces
!! Production
generated through contract
!! Materials and Components – MATERIALS
research (2012)
!! Defense and Security
© Fraunhofer / Cro & Hee
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The Fraunhofer-Gesellschaft
in Germany
Employees
© Fraunhofer / Cro & Hee
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Contract Research
(2008-2012, in ! million)
1515
1291
1340
1402
1606
95
88
Other sources
385
European Commission revenue
569
Federal and Länder
governments revenue
Industrial revenue
Institutional funding
469
2008
© Fraunhofer / Cro & Hee
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2009
2010
2011
*
2012
*2012: preliminary, 22.1.2013
Fraunhofer Alliances
Adaptronics
Energy
Additive Manufacturing
Food Chain Management
AdvanCer
Lightweight Structures
Ambient Assisted Living AAL
Nanotechnology
Automobile Production
Optic Surfaces
Battery
Photocatalysis
Building Innovation
Polymer Surfaces POLO
Cleaning Technology
Simulation
Cloud Computing
Traffic and Transportation
Digital Cinema
Vision
E-Government
Water Systems (SysWasser)
Embedded Systems
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Fraunhofer Research Units Worldwide
Glasgow
San José
East
Lansing
Plymouth
Gothenburg
Wroc!aw
Brussels
Vienna
Paris
Budapest
Bolzano Graz
London
Boston
Cambridg
Newark
e
Maryland
Porto
Beijing
Thessaloniki
Seoul
Tokyo
Cairo
Dubai
Bangalore
Salvador
Santiago de Chile
Subsidiary
Center
Representative Office
Senior Advisor
© Fraunhofer / Cro & Hee
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Selangor
Singapore
Jakarta
Sydney
Project Center / Strategic Cooperation
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
Tailor-made Solutions
© Fraunhofer / Cro & Hee
Stand März 2013
Facts and Figures of Fraunhofer ILT
!! About 30 Mio Euro operating budget
(without investments)
!! About 6 Mio Euro investments per year
!! 394 Employees
!! DQS certified according to DIN EN ISO 9001
!! 2 branches abroad :
-! Center for Laser Technology CLT
in Plymouth, MI, USA
-! Coopération Laser Franco-Allemande CLFA
in Paris, France
!! One patent application per month on average
!! Approx. 10 participations in trade fairs / 20 organized
events per year
© Fraunhofer / Cro & Hee
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Tailored Lasers for Industrial Use
Laser Beam Sources
Applications
!! Power / Energy
!! Manufacturing Technology
!! Spacial Quality
!! Measurement Technology
!! Temporal Quality
!! Spectral Quality
!! Microelectronics (EUV)
!! Life Sciences
>> Equipment of the Fraunhofer ILT
© Fraunhofer / Cro & Hee
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Structure of Fraunhofer ILT, RWTH Aachen - LLT, TOS,
NLD
© Fraunhofer / Cro & Hee
Stand März 2013
700
70
600
60
500
50
400
40
Sales 2009: 78 Mio !
30
300
20
200
10
100
0
0
1990 1991 1992 1993 1994 1995 1996 1997 1998 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Spin-offs
© Fraunhofer / Cro & Hee
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Employee
S p i n n - o ff s
Employee
Spin-offs: Fraunhofer ILT
Fraunhofer ILT - Networking
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Employees and Budgets Steinbachstraße 15
ILT
LLT / TOS / NLD
Host
Companies
Total
Employees
205
89
240
533
Research Assistants, Students
178
42
29
230
Operating Budget (Mio. !)
30,3
7
-
-
47,9 %
5%
80 %
-
Stand 2012
Industry Share (!)
© Fraunhofer / Cro & Hee
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RWTH Campus Melaten
Close Cooperation of University and Industry
Goal
"! 15 clusters
Central services
"! Congress center
"! Hotels
"! Clean rooms
Digital Photonic Production
Training
"! Graduate School
"! School of Management
"! RWTH International Academy
ILT
Life
"! Dormitories
"! Catering
"! Events
Skizze: rha reicher haase + associierte, Aachen
© Fraunhofer / Cro & Hee
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CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
Fraunhofer Cluster of Innovation »TurPro«
»TurPro«
Integrative production technology
for energy efficient turbo machines
"! Manufacturing and repair processes for
compressor and turbine components
"! Industries: Power Gen & Aerospace
"! Budget: 10.25 Mio. !
- Industry: 3.1 Mio. !
- Fraunhofer: 4.05 Mio. !
- NRW: 3.1 Mio. !
Partners:
Granted by
North Rhine-Westphalia
© Fraunhofer / Cro & Hee
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Clear Seperation between pre-competitive and
bilaterale Workpackages in the Innovationscluster
Bilateral Technology
development
!! R&D – Contract,
!! General agreement or
!! General terms and conditions from FhG
Pre-competitive Technology
development
!! Contract together
© Fraunhofer IPT/
Fraunhofer ILT
Seite 20
Tip Repair of Turbine Blades
Tip Repair of Turbine Blades
»CAx-Framework«
Optical
Metrology
Machining
and Preparation
Laser Deposition Welding
and
Process Monitoring
Universal Clamping Solution
Page 21
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Reshaping
Adaptive Milling
Process Implementation at MDT
Page 22
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Process Implementation at MDT
Page 23
© Fraunhofer / Cro & Hee
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Process Chain for Manufacture of Compressor Blades by
LMD
Additive Manufacturing of Compressor Blades
Laser metal
deposition
Geometrical data
aquisition
Adaptive
generation of
tool paths
Final machined
Milling
Additive
manufactured
»CAx-Framework«
Build-up rate: 42 mm3/s
Process time: tLaser = < 2min
Page 24
© Fraunhofer / Cro & Hee
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Case study „LMD of a BLISK“
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Process-chain for Repair – Tip Repair
LDM
Optical
measurement
Process-chain for:
GT-Blade
!! Integrated software
platform
!! Integrated clamping
system
Geometrical
data acquisition
Laser
CAx
Framework
Preparation by
milling
Melt pool
detection
Clamping
Process
monitoring
Machining
© Fraunhofer IPT/
Fraunhofer ILT
© Fraunhofer / Cro & Hee
Stand März 2013
Finishing by
milling
Geometrical
data acquisition
Optical
measurement
LMD of Near Net-shape HPC Blade Mock-ups
1
LMD
Process strategy
development
2
LMD
CAx
implementation
3
Geometry
data acquisition
Machining
Feedback
CAD
Mod
© Fraunhofer IPT/
Fraunhofer ILT
© Fraunhofer / Cro & Hee
Stand März 2013
el
Near-net-shape build-up of BLISK blade mock-ups
Joint process strategy development @ IPT/ILT
Implementation of process layout in CAx-framework
Oversize (- 0,05 – (+) 1,2 mm) by LMD
Finish machining
Pre finish machining
Rough machining
LMD
Adaptation of NC
strategy and
improvement of
clamping
© Fraunhofer / Cro & Hee
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Repair of Compressor and Steam Turbine Components
Radial compressor
Axial compressor
LMD of bearing areas
of shafts from radial
and axial
compressors and
steam turbines
Steam turbine shaft Source: MAN Diesel & Turbo SE
© Fraunhofer / Cro & Hee
Stand März 2013
Repair of Compressor and Steam Turbine Components
Source: MAN Diesel & Turbo SE
© Fraunhofer / Cro & Hee
Stand März 2013
Thanks for your Attention!
Visit us!
!!
!!
!!
!!
!!
!!
!!
UKP Workshop, Aachen
Hannover Messe, Hannover
LASER, München
ICALEO, Anaheim
K, Düsseldorf
EuroMold, Frankfurt
productronica, München
Fraunhofer Institute for Laser Technology ILT
Steinbachstraße 15, 52074 Aachen, Germany
+49 241 8906-0
info@ilt.fraunhofer.de
www.ilt.fraunhofer.de
© Fraunhofer / Cro & Hee
Stand März 2013
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
Cluster of Excellence
Integrative Production
Technology for High-Wage
Countries
RWTH Aachen University
June 12, 2014
page 33
German Research Foundation (DFG)
Excellence Initiative
Key figures of the second phase (2012-1017)
!! Total funding: 2.4 Billion Euros
!! Funded projects: 99 projects at 39 universities
–! 11 Institutional Strategies (“Excellent Universities“)
–! 43 Clusters of Excellence
–! 45 Graduate Schools
“RWTH 2020: Meeting Global Challenges”
!! Clusters of Excellence
–! "Integrative Production Technology for High-Wage
Countries“
–! “Tailor-Made Fuels from Biomass" (TMFB)
!! Graduate Schools
Source: DFG
–! “Aachen Institute of Advanced Study in Computational
Engineering Science” (AICES)
page 34
Cluster of Excellence
Integrative Production Technology at RWTH Aachen University
Cluster of Excellence
Participating Institutions
"! 77 Mio. ! budget (2006 – 2017)
"! 32 professors
"! 82 funded staff
"! 158 doctoral theses completed
within the area of the Cluster
"! 7 researchers of the cluster became
professors
page 35
Research Objective of the Cluster
Resolution of the Polylemma of Production
Market-oriented view
Resource-oriented view
Economies of scale
Planning orientation
!! Synchronised processes
!! Centralised knowledge
management
!! High frequency
production cycle
2020
Scope
vs.
2006
Economies of scope
!! Flexibility and versatility
product creation chains
deterministic models
Value
vs.
!! Dynamic and complex
!! Integration of virtual
Value orientation
!! Decentralised near-
Plan
Time
Scale
process decision making
!! Standardised methods
page 36
Research Fields of the integrative production technology
On the road to „Industry 4.0“
Individualised Production
Selfoptimising Production Systems
Value
Scope
Plan
Virtual Production Systems
Scale
Time
Integrated Technologies
page 37
Collaboration Productivity
Research Objective of the Cluster
Individualised Production
Selfoptimising Production Systems
Radically short product
development processes
Better performing
than engineered
Return on Engineering
!
Return on Production
!
Integrative
production
technology
Value
Scope
Integrative
production
technology
today
today
#
#
Plan
Time
Scale
Virtual engineering of
complete value chains
Revolutionary short value chains
Virtual Production Systems
Integrated Technologies
page 38
Collaboration Productivity
Research Objective of the Cluster
Return on Engineering
€
Radical short product
development
processes
Integrative
production
technology
Return on Production
Better performing
than engineered
€
Integrative
production
technology
today
today
#
#
Virtual engineering of
complete value chains
Revolutionary short
value chains
page 39
Individualised Production
Radical short
product development
processes
Agile Product Development
New Business Models
Better performing
than engineered
Virtual engineering
of complete value
chains
Return on Engineering
Revolutionary short
value chains
Return on Production
page 40
Revolutionary short product development processes
Using inverse design for dies and super computers
Inverse design of profile extrusion dies
Using the super computer in Jülich for tool
optimization
Quelle: http://www.fz-juelich.de/portal/DE/Forschung/Informationstechnologie/Supercomputer/JUROPA.html;jsessionid=3F563012C2BC24186A62AFD1B972E1D1?nn=363164
page 41
Virtual Production Systems
Return on Engineering
Return on Production
Radical short
product development
processes
Virtual engineering of
complete value chains
Better performing
than engineered
Revolutionary short
value chains
Virtual Production Intelligence
Integrated Computational Materials and Production
Engineering
page 42
Complete virtual value chains
AixViPMaP – Aachen (Aix) Virtual Platform for Materials and
Processes
Integration of
Machining
Annealin
g
Forging
Machining
Carburising
Welding
sub-"
micro
macro
Rolling
Thermodynamical data bases
Comprehensive, standardised, modular and extendable modeling platform
being efficiently adaptable to a specific material, process-chain and
product
page 43
Integrated Technologies
Return on Engineering
Return on Production
Radical short
product development
processes
Better performing
than engineered
Complete virtual
value chains
Revolutionary short
value chains
Integration of Production Steps
Multi-Technology Production Systems and Products
page 44
Revolutionary short value chains
Incremental sheet metal forming
-85%
Movie: Manufacturing of a hatch for Audi A4 Avant
shorter process chains*
Door Frame Airbus A320
Incremental sheet metal forming:
Integration of laser, flanging, trimming,
,...
joining,...
Cross Member
Audi Q5
Quelle: medium number of process steps today 6,7
page 45
Selfoptimising Production Systems
Intelligent Networks
Better performing
than engineered
Adaptive, cognitive Systems
Radical short
product development
processes
Virtual engineering
of complete value
chains
Return on Engineering
Revolutionary short
value chains
Return on Production
page 46
Performing selfoptimised better than engineered
Selfoptimising Assembly Systems
Cognitive assembly cell
Weaving processes
Control of
processes
Assembly System
Determinate model of interacting systems
Decision unit
Assembly of big parts
Slab-Laser-Assembly
Model builder
Machine Control
Local controller
Actuator
Sensor
Controlled system
page 47
Selfoptimising Production Systems
The Use of High-Resolution Data from
Production increases the quality of data
in the IT-systems
Cloud based and real-time capable
simulation of processes for fast and wellfounded decisions
The use of integrated sensoric in the
production must be increased in order to
increase the transparency about production
processes in real time and to create a wellfunded decision basis.
Simulation platforms empower employees to
estimate consequences, understand the
complexity and decide in a better way!
Picture Source: Test set-up at SICK AG
page 48
Cluster management structure for the 2nd funding period
Scientific Board
Steering Committee
Scientific Advisory Board
Industrial Advisory Board
Consulting
Decision
Cluster Management (Prof. Brecher / COO / CFO)
scientific collaboration, education, equal opportunities, transfer, controlling
ICD A Coordinator
Prof. Hopmann
ICD B Coordinator
Prof. Schulz
ICD C Coordinator
Prof. Hirt
ICD C Board
ICD D Coordinator
Prof. Schlick
ICD A Board
ICD B Board
ICD D Board
Prof. Poprawe
Prof. Jeschke
Prof. Brecher
Prof. Schuh
Research Area A-2
Research Area B-1
Research Area C-2
Research Area D-1
Prof. B.-Polaczek
Prof. Bleck
Prof. Bobzin
Prof. Klocke
Research Area A-3
Research Area B-2
Research Area C-3
Research Area D-2
Cross Sectional Processes
Leverage sustainability
CSP 1: Prof. Jeschke
Scientific Cooperation Engineering
CSP 2: Prof. Schuh
Production Theory
CSP 3: Prof. Brecher
Prof. Schmitt
Technology Platforms
Research Area D-3
page 49
Cluster management structure for the 2nd funding period
Scientific and Industrial Advisory Board
Scientific Board
Steering
!! 30 members
ofCommittee
leading international research institutions
Scientific Advisory Board
Industrial Advisory Board
and national authorities
Consulting
Decision
!! 35 members of leading, innovative international
companies
and/ associations
Cluster Management ((Prof.
Brecher / COO
CFO)
scientific collaboration, education, equal
opportunities,and
transfer,
controlling of
!! Evaluation
discussion
ICD A Coordinator
Prof. Hopmann
ICD B Coordinator
Prof. Schulz
the scientific progress
ICD C Coordinator
D Coordinator
!! Evaluation
andICD
discussion
of business
technology
Prof. Hirt
Prof.
Schlick
Crossand
Sectional
Processes
Leverage sustainability
cases
within the Technology
Platforms
ICD C Board
ICD D Board
ICD A Board
ICD B Board
Prof. Poprawe
Prof. Jeschke
Prof. Brecher
Prof. Schuh
Research Area A-2
Research Area B-1
Research Area C-2
Research Area D-1
Prof. B.-Polaczek
Prof. Bleck
Prof. Bobzin
Prof. Klocke
Research Area A-3
Research Area B-2
Research Area C-3
Research Area D-2
CSP 1: Prof. Jeschke
Scientific Cooperation Engineering
CSP 2: Prof. Schuh
Production Theory
CSP 3: Prof. Brecher
Prof. Schmitt
Technology Platforms
Research Area D-3
page 50
Cluster of Excellence
Scientific Cooperation
Communication and networking platform, e.g. international working group on Hybrid Production
Systems
Business unit of Aachen’s
Fraunhofer IPT/ ILT
Cooperation with the Finnish Metals and
Engineering Competence Cluster
FIMECC and the University of Tampere
University partnership
& exchange
agreement
Strategic cooperation
and exchange
agreement
Strategic cooperation
in Production
Technology
Strategic cooperation in
Production Technology
Strategic cooperation in
Production Technology
and
exchange agreement
page 51
Industrial Advisory Board
BorgWarner Turbo Systems,
Kirchheimbolanden
SEW Eurodrive GmbH & Co. KG,
Langenfeld
RKW SE, Frankenthal
Phoenix Contact GmbH & Co. KG,
Blomberg
Maschinenfabrik Bernard Krone
GmbH, Spelle
Trumpf GmbH & Co. KG, Ditzingen
Festo AG & Co. KG, EsslingenBerkheim
ROFIN-SINAR Laser GmbH, Hamburg
ABB AG Forschungszentrum,
Ladenburg
ASMET, Loeben
EADS Deutschland GmbH, Ottobrunn
Heidelberger Druckmaschinen GmbH,
Langenfeld
Thyssen Krupp Steel Europe AG,
Duisburg
Salzgitter Mannesmann Grobblech
GmbH, Mülheim
Lanxess Deutschland GmbH,
Dormagen
Airbus Operations GmbH, Hamburg
Philips Lighting B. V., Eindhoven (NL)
SMS Siemag AG, Düsseldorf
German Engineering Federation
(VDMA), Frankfurt
MAGMA GmbH, Aachen
Siemens AG, Erlangen
BMW Group, Regensburg
Plastics Europe Deutschland e.V.,
Frankfurt
German Automobile Industry
Association (VDA), Frankfurt
Gallus Ferd. Rüesch AG, St. Gallen
DECKEL MAHO GmbH, Pfronten
CemeCon AG, Würselen
Robert Bosch GmbH, Stuttgart
Garman Machine Tool Builders‘
Association (VDW), Frankfurt
EPLAN Software & Service GmbH & Co.
KG, Monheim
PSIPENTA Software Systems
GmbH, Berlin
page 52
Contact
Dipl.-Ing. Denis Özdemir
Managing Director of the Cluster of Excellence
"Integrative Production Technology for High-Wage
Countries"
Werkzeugmaschinenlabor WZL der RWTH Aachen
Lehrstuhl für Werkzeugmaschinen
Steinbachstr. 19
D-52074 Aachen
Tel.: +49-(0)241-80-27590
d.oezdemir@wzl.rwth-aachen.de
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
© Fraunhofer / Cro & Hee
Stand März 2013
RWTH Aachen University
Research Campus Digital Photonic Production
Prof. Dr. Reinhart Poprawe,
Christian Hinke
BMBF Research Campus initiative – Background
A Research Campus is characterized by
combining the following features:
!! pooling of competences from industral and
governmental research at one location
!! Progressing of subjects in middle- and
longterm perspectives
!! A mandatory government-private partnership
Funding
!! 10 winners out of a nationwide contest
!! Funding period: 3 x 5 years
!! Funding amount: 2 M ! per year per campus
Research Campus Digital Photonic Production –
Concept and Structure
RWTH Aachen
Fraunhofer
Industry
Fundamental research
Application-oriented research
Status Quo
!!
Joint, application-oriented and integrated
research
!!
Separated fundamental research approaches
- RWTH (established posts, DFG)
- Initial research within industrial companies
- Strategic research within FhG
Product
Research Campus Digital Photonic Production –
Concept and Structure
Application-oriented
integrated research
RWTH Aachen
Fraunhofer
Industry
Fundamental research
Application-oriented research
Status Quo
!!
Joint, application-oriented and integrated
research
!!
Separated fundamental research approaches
- RWTH (established posts, DFG)
- Initial research within industrial companies
- Strategic research within FhG
Product
Research Campus Digital Photonic Production –
Concept and Structure
Application-oriented
integrated research
Research building
CDPP
RWTH Aachen
Fraunhofer
Industry
Fundamental research
Application-oriented research
Status Quo
!!
Joint, application-oriented and integrated
research
!!
Separated fundamental research approaches
- RWTH (established posts, DFG)
- Initial research within industrial companies
- Strategic research within FhG
Product
Research Campus Digital Photonic Production –
Concept and Structure
Application-oriented
integrated research
Research building BMBF Research Campus
Digital Photonics Production
CDPP
RWTH Aachen
Fraunhofer
Industry
Fundamental research
Application-oriented research
Status Quo
Product
Research Campus Digital Photonic Production
!!
Joint, application-oriented and integrated
research
!!
Separated fundamental research approaches !!
- RWTH (established posts, DFG)
- Initial research within industrial companies
- Strategic research within FhG
!!
Joint, long-term und coordinated fundamental
research
Assignment of strategic own ressources
- RWTH (established posts, Infrastructure, DFG)
- Fraunhofer (Personnel, Infrastructure)
- Industry (Personnel, Infrastructure, Cash)
Research Campus Digital Photonic Production –
Concept and Structure
RWTH Aachen Campus Cluster PP
Application-oriented
integrated research
Research building BMBF Research Campus
Digital Photonics Production
CDPP
RWTH Aachen
Fraunhofer
Industry
Fundamental research
Application-oriented research
Status Quo
Product
Research Campus Digital Photonic Production
!!
Joint, application-oriented and integrated
research
!!
Separated fundamental research approaches !!
- RWTH (established posts, DFG)
- Initial research within industrial companies
- Strategic research within FhG
!!
Joint, long-term und coordinated fundamental
research
Assignment of strategic own ressources
- RWTH (established posts, Infrastructure, DFG)
- Fraunhofer (Personnel, Infrastructure)
- Industry (Personnel, Infrastructure, Cash)
Research Campus Digital Photonic Production –
Incentive funding by BMBF
!! BMBF does not directly fund a Research Campus
# instead: funding of topical research projects within one Research Campus
!! 2 M ! funding amount per year
!! Allocation
- 1 M ! for scientific partners (RWTH and Fraunhofer)
- 1 M ! for industrial partners
!! Calculation base for industrial partners
- up to 50 k! funding for each industrial research scientist dispatched to the Research
Campus
!! Example for research scientist from industrial partner (WW) at the Research Campus
- WW has to work min. 50% of yearly net-working hours on the joint project on-site
at the Research Campus
!! Funding of the topical assigned research scientist from scientific users (RWTH and
Fraunhofer): 100%
Digital Photonic Production –
Production 2.0 – Third Industrial Revolution – Industry 4.0
The Economist, April 2012
Digital Photonic Production – Vision
“From Bits to Photons to Atoms”
Laserlight is unique
!! Highest power-density
!! Shortest pulse
!! Highest velocity
!! Mass- and contactless
!! Best controllability (CAD#Product)
Digital Photonic Production – An industrial revolution?
Cost
Cost
Conventional
production
Conventional
production
Lot size
Product complexity
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Individualisation for free
Cost
Laserbased manufacturing
Conventional
production
Laserbased manufacturing
Conventional
production
Lot size
Product complexity
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Individualisation for free
Cost
Laserbased manufacturing
Laserbased manufacturing
Digital
Photonic
Production
Digital
Photonic
Production
Conventional production
Conventional
production
Lot size
SLM 1-3 cm3 / min
Product complexity
LMD 10-30 cm3 / min
Ablation 0,2-0,5 cm3 / min
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Individualisation for free
Cost
Digital
Photonic
Production
Digital
Photonic
Production
Conventional
Production
Conventional
production
Lot size
Product complexity
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Individualisation for free
Cost
Digital
Photonic
Production
Digital
Photonic
Production
Conventional
Production
Conventional
production
Lot size
Innovative business model
Product complexity
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Complexity for for
freefree
Individualisation
Cost
Digital
Photonic
Production
Digital
Photonic
Production
Conventional
production
Conventional
production
Lot size
Innovative business model
Product complexity
Digital Photonic Production – An industrial revolution?
Individualisation for free
Cost
Complexity for for
freefree
Individualisation
Cost
Digital
Photonic
Production
Digital
Photonic
Production
Conventional
production
Conventional production
Lot size
Innovative business model
Product complexity
Innovative products
Research Campus Digital Photonic Production –
Longterm research subjects
Beam
source
Longterm integrative objectives
!! Most complex geometries
=> Direct Photonic Production
!! Higest diversity of materials
=> Femto Photonic Production
!! Highest precision
=> Nano Photonic Production
Digital Photonic Production
Longterm technology fields
Geometry
Material
Precision
!! Beam source
Direct PP
Femto PP
Nano PP
Beam source
!! Beam control
!! Interaction between
light, material and component
Beam steering
Correlation
Research Campus Digital Photonic Production –
Direct Photonic Production
Longterm integrative objectives
!! Most complex geometries
=> Direct Photonic Production
!! Higest diversity of materials
=> Femto Photonic Production
!! Highest precision
=> Nano Photonic Production
Digital Photonic Production
Beam source
Beam steering
Correlation
Geometry
Material
Precision
Direct PP
Femto PP
Nano PP
Research Campus Digital Photonic Production –
Femto Photonic Production
Longterm integrative objectives
!! Most complex geometries
=> Direct Photonic Production
!! Higest diversity of materials
=> Femto Photonic Production
!! Highest precision
=> Nano Photonic Production
Digital Photonic Production
Beam source
Beam steering
2 mm
Correlation
Geometry
Material
Precision
Direct PP
Femto PP
Nano PP
Research Campus Digital Photonic Production –
Nano Photonic Production
Longterm integrative objectives
!! Most complex geometries
=> Direct Photonic Production
!! Higest diversity of materials
=> Femto Photonic Production
!! Highest precision
=> Nano Photonic Production
Digital Photonic Production
Beam source
Beam steering
Correlation
Geometry
Material
Precision
Direct PP
Femto PP
Nano PP
Research Campus Digital Photonic Production –
Joint research under one roof
RWTH Aachen Cluster Digital Photonic Production –
Joint research under one roof
Research Campus Digital Photonic Production –
Fundementals of cooperation under one roof
!! Coordination by RWTH Campus
Photonics
Digital Photonic Production
Technology Roadmaps
Direct PP
Femto PP
Nano PP
Beam source
!! Commitees with equal representation:
RWTH, Fraunhofer, Industry
!! Joint definition of topical Roadmaps:
- Technology Roadmaps
- Integrative Roadmaps
Beam control
Correlation
Integrative Road-Maps
!! Planned joint DPP-AGs and
BMBF - start alliances
- Direct PP
- Femto PP
- Nano PP
!! Joint and coordinated definition of
research topics
- Joint DPP-AGs
- Joint research proposals (e. g. AiF)
- Coordinated, individual
research application (e. g. DFG)
Research Campus Digital Photonic Production –
Synergetic forms of cooperation under one roof
Joint Research in DPP-AGs
Digital Photonic Production
Technology Road-Maps
Direct PP
Femto PP
Nano PP
!! Joint usage of results
Beam source
!! Equipment and machines provided by
partners
Beam control
!! Elegible for funding
Correlation
Integrative Road-Maps
Joint research
in DPP-AGs
!! Fundamental research oriented, precompetetive
Complementary Research in DPP
!! Exclusive usage of results
Complementary
research at
Research
Campus DPP
!! Usage fees for equipment and
machines
!! Restricted publication
Research Campus Digital Photonic Production –
Research in joint workgroups (DPP-AG)
!! Straightforward and faithful cooperation on working plane
!! Joint defintion of relevant subjects
!! Focus on pre-competetive, fundamental-oriented subjects
!! Focus on publication, base for bilateral cooperation
!! Possibility for doctorate for research partners from the economy
!! Joint utilisation of machines and equipment provided by partners
(in-kind contribution or on rental basis)
!! Joint utilisation of results
!! All partners in one workgoup receive a non-exclusive and underlicensable
(Not to direct competitors in field of application) legal right of use on all
joint results
Research Campus Digital Photonic Production –
Fundamentals of result-utilisation
Partner
E
Partner D
Background
Joint research in
joint workgroups (DPP-AGs)
- Only non-exclusive utilisation/licensing
- Fundamental oriented research topics
Complementary reasearch by partners in
Research Campus DPP
(single or bilateral)
- Also exclusive utilisation/licensing
- Application oriented research topics
- Also product development possible
(not elegible for funding)
!! Cooperation by longterm contracts
!! Research scientists work under one roof, but stay in their organization
!! Defintion of research roadmaps in commitees with equal representation
Research Campus Digital Photonic Production –
Longterm business model
!! Partner from industry and science obtain benefits from spacial vicinity and
synergetic effects
!! Industrial partners hire and pay their own employees and dispatch them to
the Research Campus
!! Industrial and scientific partners provide machines and equipment (Partially
on loan)
!! Industrial and scientific partners jointly define the topics, in which the
synergy effects exceed opportunity costs (By dispatching employee(s) to
Research Campus)
!! Usage of incentive funding within up to 15 years
!! Partners apply together for funding opportunities (e. g. BMBF, AiF, EU) and
establish funded projects together at the Research Campus
!! Partners (industrial and scientific) jointly work research topics defined by the
industry
Research Campus Digital Photonic Production –
Distinction from classic joint research
Classic joint research
Research Campus
!! Distributed research
=> Transfer of explicit knowledge
!! Joint research on site
=> Transfer of implicit knowledge
!! Operative perspective
!! Strategic perspective
!! Funding period max. 3 years
!! Funding period up to 15 years
!! Singular funding opportunity
!! Joint topic definition
!! Network development
!! Recruiting
!! Risk sharing
Research Campus Digital Photonic Production –
Usage of infrastructure in joint DPP-AGs
!! Mandatory rental of at least one office (20 m$)
!! All-inclusive rent: approx. 25 ! / m$
(includes: heating, energy, network access,
parking lot, conference rooms, reception)
!! Mandatory usage and payment of min. 15
days of machine-time per year per dispatched
industrial employee
!! Each DPP-AG jointly utilizes the rented
machine-time
!! Additional booking of machine-time possible
(based on needs and capacity)
!! General machine-time costs:
1000,- ! / day
Research Campus Digital Photonic Production –
Example: SLM-Equipment
EOS
M270
PL% 200 W
ILT
laboratory machine
TrumaForm
PL% 1000 W
PL% 500 W
SLM Solutions
280 HL
PL1% 400 W
PL2% 2000 W
ILT
laboratory machine
PL% 1000 W
PL% 200 W
Realizer SLM50
PL% 120 W
Concept
M1
PL% 400 W
Research Campus Digital Photonic Production –
Building view
Research Campus Digital Photonic Production –
Building view
Research Campus Digital Photonic Production –
Status Quo of the BMBF Research Campus initiative
Current state and time schedule
!! Official start of pre-stage
8/1/2013 by state secretary Mr. Rachel
!! Pre-stage
1/1/2013 – 30/6/2013
!! Submission of research roadmaps
September 2013
!! Defintion of research projects
September 2013
!! Submission of cooperation contracts
September 2013
!! Start of main stage
Estimated 1/1/2014
Research Campus Digital Photonic Production –
Incentive funding by BMBF
!! BMBF does not directly fund a Research Campus
# instead: funding of topical research projects within one Research Campus
!! 2 M ! funding amount per year
!! Allocation
- 1 M ! for scientific partners (RWTH and Fraunhofer)
- 1 M ! for industrial partners
!! Calculation base for industrial partners
- up to 50 k! funding for each industrial research scientist dispatched to the Research
Campus
!! Example for research scientist from industrial partner (WW) at the Research Campus
- WW has to work min. 50% of yearly net-working hours on the joint project on-site
at the Research Campus
!! Funding of the topical assigned research scientist from scientific users (RWTH and
Fraunhofer): 100%
Research Campus Digital Photonic Production –
“From Bits to Photons to Atoms”
Thank you very much for your
attention
Christian Hinke
christian.hinke@llt.rwth-aachen.de
+49-241-8906-352
CONTENTS
1.! Fraunhofer Profile
2.! Fraunhofer Institute for Laser Technology ILT
3.! Fraunhofer Cluster of Innovation >>TurPro<<
4.! Cluster of Excellence RWTH
5.! Research Campus Digital Photonic Production >>DPP<<
6.! Aachen Center for 3D Printing
Thank you for your attention!
Any questions
Fraunhofer Institute for Laser Technology ILT
Aachen, Germany
Dr. -Ing. Damien Buchbinder
Phone: +49-(0)241/8906-488
Fax: +49-(0)241/8906-121
damien.buchbinder@ilt.fraunhofer.de
www.ilt.fraunhofer.de