In the research field of process control and design, employees deal with overarching issues that arise from the use of additive manufacturing in production systems. The focus here is on the investigation of the fundamental cause-effect interdependencies in additive manufacturing processes using process monitoring methods. In addition, the interactions of the additive manufacturing process with upstream and downstream processes in the process chain are considered. This includes, for example, the adaptation of additive manufacturing processes for the production of medical implants and damping microstructures or the modification of the processes taking into account the process gas influence.
Head of Research Field: Lukas Melzig
Using numerical methods, the members of the research field of digital additive manufacturing investigate how additive manufacturing processes can be simulated. On the one hand, the application-oriented analysis on the component level, such as the control of component distortion and failure, is addressed. On the other hand, mechanisms on the meso and micro level are investigated - including the formation of shrink lines or the formation of the microstructure. In addition, members of the research field are concerned with the efficient prediction of component structural behavior. The aim is to improve the design of additive components in a process-oriented manner. Another research topic deals with topology optimization, which is used to evaluate the component quality regarding force flow and mass optimization.
Head of Research Field: Kai-Uwe Beuerlein
The performance of battery cells depends not only on the materials used, but also on the composition and the structure of the electrodes. Each electrode material requires a new design of the manufacturing processes, which is why a deeper understanding of these is necessary. The processes considered within the research group range from powdered active material to the finished electrode and include mixing and dispersing, coating and drying as well as calendering and laser structuring of the electrodes.
In the research field of electrode design and fabrication, employees are working intensively on new electrode designs (from slurry formulations to electrode structures) and the processing of new electrode materials. On the cathode side, the focus of research is primarily on low-cobalt materials based on NMC and NCA as well as prelithiated manganese-rich high-voltage spinel. For anode materials, research focuses on silicon composites and the prelithiation of anodes.
In addition to materials research and research on electrode slurries, the iwb also deals with the design of electrode and cell designs. The focus here is on artificially generated electrode structures using mechanical structuring processes and laser structuring, as well as naturally generated structures using different porosities within the electrode layers.
Head of Research Field: Elena Jaimez Farnham
The research field Process Chains and Digital Production focuses on the interaction of all processes along the entire value chain from material integration to scalable, digitalized production.
At its core lies the question of how innovative cell concepts can be efficiently transferred into industrial process chains. In the area of scaling, this includes a holistic consideration of the drop-in capability of sodium-ion batteries, the upscaling of solid-state batteries, and strategies for prelithiation, always with a focus on their integration into existing and future production lines. Data competency connects all process steps: Through comprehensive cell testing, tracking & tracing, and the digitalization of the production line, consistent data spaces are created that enable cross-process analysis, control, and optimization. At the same time, data-driven approaches make a decisive contribution to quality assurance and scrap reduction by detecting deviations at an early stage and stabilizing processes in real time. This establishes the foundation for an intelligent, adaptive, and low-scrap production. In addition, the research field addresses sustainability and economic efficiency at the system level. Cost modeling and benchmarking against industrially manufactured lithium-ion batteries enable a well-founded evaluation of entire process chains and not just individual steps.
The research is enabled by the unique infrastructure at the iwb: A modern, digitalized pilot production line in a dry-room atmosphere for various cell chemistries, as well as a specialized line under inert gas conditions for solid-state batteries, which provides the basis for realistically mapping and further developing complete process chains. Thus, the research field Process Chains and Digital Production acts as a linking element between detailed process understanding and industrial implementation, with the goal of realizing holistic, scalable, and economically viable battery manufacturing.
Head of Research Field: Johannes Schachtl
The transformation of production requires new approaches to future-proof production systems: We develop methods for maturity assessment, change management, work design, transformation strategies, and implementation concepts for innovations such as artificial intelligence. In doing so, we design production systems that are resilient and competitive in the long term, integrate innovations, and successfully address global challenges.
Head of Research Field: Olivia Bernhard
The research field Production Management relies on data-driven methods across all levels of production: from shop floor management to production planning and control, and on to factory planning and supply chain interfaces. The focus is on AI- and simulation-based approaches for process optimization, layout and scenario analysis, and resilient, predictive control of production systems. Our goal is to secure sustainable value creation and increase productivity through intelligent data utilization.
Head of Research Field: Julian Stang
We believe that it takes manufacturing companies to drive the transition to a circular economy. With our circular economy research field, we support companies in their first steps towards a circular economy and optimize existing systems. This includes research into methods and technical solutions for the design and evaluation of circular products, the planning and implementation of end-of-life processes such as disassembly and remanufacturing, and the design of circular factories and production networks. Our interdisciplinary team includes employees from the Sustainable Production, Production Management and Logistics, Assembly Technologies and Robotics departments.
Contact: circular.economy@iwb.tum.de
We investigate how the key principles of energy sustainability (sufficiency, efficiency and consistency) can be implemented in factories. To this end, we develop approaches to reduce unnecessary energy demands, to efficiently supply the essential useful energy, and to cover the overall energy demand with renewable sources. Our methodological approach relies on discrete time series analyses, mathematical modeling, life cycle analyses, and cost calculations.
Head of Research Field: Markus Wörle
Current research covers a broad spectrum of laser-based manufacturing processes, which are the focus of the research field ‘Laser Manufacturing Technology’. A focus is the application of laser manufacturing technology in energy storage and conversion systems. For example, laser-based processes are being applied in various projects at the iwb along the production chain for lithium-ion batteries and solid-state batteries. In addition, the use of laser manufacturing technology along the hydrogen process chain in electrolysers and fuel cells is being investigated. Thanks to the wide range of available sensor systems, laser manufacturing processes can be monitored and continuously improved.
Head of Research Field: Pawel Garkusha
The research field focuses on the investigation and automation of the entire development process of digital twins for machine tools (machine twin and process twin). This starts with the systematic acquisition of data and ends with automated decision-making through the use of AI models.
Head of Research Field: Daniel Piendl
The research field Process Behavior addresses current challenges in the machining of metallic materials. A particular focus is on hybrid process chains in which subsequent milling improves the component quality. Solutions are being developed for the machining post-processing of additively manufactured components (e.g., for remanufacturing purposes) as well as for the machining post-processing of components that are difficult to form.
Head of Research Field: Moritz Göldner
This research area deals with complex applications that are difficult to automate in conjunction with classic automation technology such as robots, control systems, and planning processes. The focus is on data-driven methods that enable informed decisions and optimized processes through the evaluation and use of available data. The target applications include the automation of complex processes and tasks, particularly in assembly, as well as classic automation processes and quality assurance processes. The focus is on the development of closed systems within whose defined boundaries processes can run automatically. A particular focus is on dealing with uncertainties in the underlying data. In addition, the aim is to develop digital solutions that can also be used reliably in dynamic assembly processes.
Head of Research Field: Stephan Trattnig
The Adaptive Robotics research field deals with flexible robot systems consisting of robots, sensors, and peripherals as an integrated overall system. The focus is on adaptivity—both in development, through generic, application-independent methods, and in application, for example, in situational adaptation during commissioning on site. The goal is to create scalable solutions that can automate complex tasks, regardless of the specific application.
Head of Research Field: Johannes Bauer