TOMORROW‘S TECHNOLOGIES. TODAY. · pipeline! « prof. dr.-Ing. michael Rethmeier Joining and coating technology ranks among the most important steps within a process chain in industry

MF 1

F R A U N H O F E R I N s t I t U t E F O R p R O d U c t I O N s y s t E m s A N d d E s I g N t E c H N O l O g y I p k

TOMORROW‘S TECHNOLOGIES. TODAY.

2 3

Profile 04

Aims 06

Divisions

CorporateManagement 08

VirtualProductCreation 10

ProductionSystems 12

JoiningandCoatingTechnology 14

AutomationTechnology 16

QualityManagement 18

MedicalTechnology 20

CompetenceCenters 22

OurServices 24

OurApproach 26

OurCustomers 28

OurPartners 29

FraunhoferInnovationClustersatIPK 33

FraunhoferIPKinFactsandFigures 34

YourContact 35

HowtoFindUs 36

Imprint 37

c O N t E N t

08CorporateManagement

10VirtualProductCreation

16AutomationTechnology

14JoiningandCoatingTechnology

12ProductionSystems

20MedicalTechnology

18QualityManagement

2 3

TOMORROW’S TECHNOLOGIES. TODAY.TheFraunhoferInstituteforProductionSystemsandDesignTechnologyIPKpromotesexcel-

lenceinproductionscience.Ourinternationalandinterdisciplinaryteamhasbeendelivering

appliedresearchanddevelopmentservicestoresearchpartnersandcustomersforover30

years.Wecovertheentireproductlifecycle–fromtheproductconcept,toitsdevelopment,

layoutandmanufacturing,rightthroughtorecyclinganddisposalandthemanagementof

theseprocesses.

Ourapproachtodevelopingprocessesandtechniquesisholistic.Wecombinesoundeconomic

principlesandsophisticatedtechnologywithecologicalconsiderations,suchassustainability

andenvironmentalcompatibility.Alargepartofoursuccessistheinnovativenessandcom-

mitmentofourstaff,whichiswhywearealwayslookingtothenextgenerationofcreative

scientistsbypromotinglong-termtraininginspecificknow-howforourcorecompetenciesin

management,productcreation,theproductionprocessandthedesignofindustrialplants.

Thisportfolio»Tomorrow‘sTechnologies.Today.«introducesourbusinessdivisions,provid-

inganoverviewofourservicesandinsightintoourapproach.Feelfreetocontactusformore

informationaboutanyofourservices.

Prof.Dr.h.c.Dr.-Ing.EckartUhlmann

3

E d I t O R I A l

4 5

TURN OUR KNOW-HOW INTO YOUR COMPETITIVE EDGE

p R O F I l E

4 5

FraunhoferIPKoptimizestechnologies,industrialprocesses

andthemanagementoftheseprocessesforcustomerson

acontractbasis.Weworkwiththeentireprocess,fromthe

initialidea,toitsdevelopmentandmanufacture,rightthrough

totherecyclingprocess.Thankstoourclosecollaboration

withourpartnerinstituteattheProductionTechnologyCenter

(PTC),theInstituteforMachineToolsandFactoryManage-

ment(IWF)attheTechnischeUniversitätBerlin,wenotonly

helpyoudevelopprototypes,butalsodeliverandtranslate

efficientuniversityresearchfindingsintooperationalmanage-

ment.Webelievethatsuchatechnologytransferrequiresa

holisticapproach.Forthisreason,wecombineeconomicprin-

ciplesandtechnologicalexcellencewithquestionsofsustain-

abilityandenvironmentalcompatibility.

Westrivetobringinnovativetechnologiestosmalland

medium-sizedenterprises(SMEs).TheroleofSMEsinsupply

chains,bothasdevelopmentpartnersandsystemsuppliers,is

ontherise.Increasingtheirtechnologicalcompetitivenessis

oneofourkeyaims.

6 7

TheFraunhoferInstituteforProductionSystemsandDesign

Technology(IPK)comprisessevenbusinessdivisionsconduct-

ingappliedresearchanddevelopmentforindustrialmanufac-

turing–CorporateManagement,VirtualProductCreation,

ProductionSystems,JoiningandCoatingTechnology,Automa-

tionTechnology,QualityManagement,andMedicalTechnol-

ogy.Wedevelopmethodsandtechnologiesforcorporate

management,productdevelopment,productionprocessesand

thedesignofindustrialplants.

Ourresearchcentersonprocessesthatincreaseproductivityin

thedevelopmentandrealizationofproductsandtheirtransfer

intosystemsolutions.Thisincludesdesigningandmanu-

facturingintelligentproductionequipment,integratingsuch

equipmentintocomplexmanufacturingenvironmentsand

optimizingtheiremployment.Furthermore,wedevelopnew

applicationsincutting-edgefields,suchassecurity,mobil-

ityandmedicaltechnology.Apartfromourin-houseapplied

research,wealsodevelopnewsolutionsinclosecollaboration

withnationalandinternationalcompanies.Togetherwith

industrypartners,wetransferourbasicinnovationsintofunc-

tionalapplications.

A I m s

6 7

FROM INNOVATION TO APPLICATION

8 9

Acompany’ssuccessisnotsimplyduetocompetitiveproducts.Thecompaniesthatleadthe

packsecurelong-term,decisivecompetitiveadvantagesbyemployingprocessinnovations.

Theseinvolveanenterprise’sproductandserviceprocesses,aswellasitsplanningandcontrol-

lingprocesses.TheCorporateManagementdivisionresearchesthedevelopmentandimple-

mentationofinnovativeconceptsforthedesignofserviceprocessesinenterprises,manage-

ment,planningandcontrolofindustrialplantsandcorporatenetworks.Wealsodevelop

techniquesandsoftwaretoolsthatsupportcompanyplanningandcontrolinvariousindustry

andservicebranches.

Ourapproachtothesetasksischaracterizedbyaholisticunderstandingoftheenterprise,

includingitsprocesses,productsandcustomers,organizationalstructureandinformationtech-

nology,andsuppliersandcompetitors.Ourstrengthisourinterdisciplinaryapproach.Ourteam

ofengineers,engineeringmanagers,computerscientists,naturalscientists,andsocialscientists

developall-roundsolutions,fromconceptdevelopmentthroughtoimplementation,where

necessaryusingsoftware.Thedivision’soverallobjectiveiseffective,efficientandhuman-

centereddesignofperformance-relatedprocesses.

Our research and

development topics:

•Managementsystems

• Businessprocessdesign

• Enterpriseandfactory

planning

•Qualityandenvironmental

management

• Knowledgemanagement/

intellectualcapitalreporting

• Benchmarking

» Thesynchronizat ionofcompanyprocesses

wi l l becomeadecis ivecompet i t ivefactor. Weare

workingtoturnthis v is ion intoreal i ty bycoordi -

nat ingbusinessandmanagementprocesses, ICTs,

and in-houseknow-howwithinacompany.«prof. dr.-Ing. kai mertins

CORPORATEMANAGEMENT

8 9

d I v I s I O N s

CORPORATEMANAGEMENT

10 11

Digitalengineeringtechnologies,processesandmethodsinproductplanning,productdevelop-

ment,manufacturingengineering,andinMRO(maintenance,repairandoverhaul)aremean-

whileindispensableinindustrytomeettime-to-market,costandqualitytargets.Thedivision

VirtualProductCreationsupportscompaniesandpartnernetworksinindustryandpublicsec-

torstomosteffectivelyimproveandoptimizetheirportfolioofvirtualengineeringPLMsolution

elements(process,methods,toolsandinformationstandards).ConsultingandR&Dservices

ofthedivisionVirtualProductCreationcompriseneutraltechnologystudies,digitalprocess

analysis,IT-integrationarchitecturedevelopment,engineeringmethoddevelopment,andtool

demonstratorsinthefieldsofproductdevelopment,digitalfactory,computer-aidedMROas

wellassustainabilityandend-of-lifeplanning.

IncontrasttostandardIT-consultingcompaniesortoPLMvendors,wecanoffertheexpert

neutraldeep-diveknowledgeoffutureIT-technologies,upcomingsolutionsandstandardsas

wellasdigitalbusinessandcollaborationmechanismsinindustrycaserelevantscenarios.Asa

majorassetweprovidesubstantialexperiencebasedonourcompletesetofdigitalcompeten-

ciesinPDM/PLM,engineeringcollaboration,productmodeling(fromsketch,intelligentCAD

andDMUuptoVirtualReality),cross-domainmechatronicsystemdevelopment,digitalmanu-

facturingplanning(CAM,CAP),functionalmock-upandvalidation(e.g.withspecialCAE

solutionsforflexiblecomponentsimulation),andinnovativesmarthybridprototypingbased

validationandsign-off.

» Virtual productcreat ion is a l readytodaya

growingcompetence in industrytoensureeffec -

t iveengineer ingofproducts, processesandser-

v ices. Thefuture, however, demandsmajordigita l

innovat ionstoensurerobustcontrol of product,

processandcontextcomplexity, andtoenabletrue

model basedengineer ing.«prof. dr.-Ing. Rainer stark

VIRTUAL PRODUCT CREATION

Our research and

development topics:

• Productdevelopmentmethods

andprocesses

• Productdesignandfunctional

validation

• Intuitiveinteractionwith

virtualprototypes

• Informationmanagementfor

theproductcreationprocess

• Digitalmanufacturingand

factoryprocesses

10 11

VIRTUAL PRODUCT CREATIONd I v I s I O N s

12 13

Anenterprise’suniquesellingpointsaredeterminedbycomplexproductswithhighfunctional

integration.However,onlyifmanufacturingprocessesarefullymasteredandthehighest

qualitystandardsaremaintainedcantheseproductssecureanenterprise’spositionoverthe

long-term.Atthesametime,material,tool,manufacturingprocess,machineandprocesschain

innovationsareextremelymultifaceted.Newhigh-strengthmaterialsandmaterialcomposites

alsoplacespecialdemandsontoolsandmanufacturingprocesses.Novelmachineconcepts

necessitatetheredesignofprocessingchains.Advancingminiaturizationrequiresnew,high-

precisionmachines.Duetothemanifoldinteractionsbetweentheseinnovationareas,any

solutionhastobeapproachedinaninterdisciplinaryfashionandconsideredwithintheoverall

contextofallbusinessprocesses.

ThedivisionProductionSystemsdevelops,deliversandoptimizesproductionandmanufactur-

ingtechnologiesandthemachineandcontroltechnologynecessarytomanufactureinnovative

products.Aspartofcustomercontracts,wedevelopnewmachinesandprocessingstrategies,

optimizeexistingproductionsystemsandcreatefuture-orientedtoolconcepts.Furthermore,we

supportmanufacturersinthedevelopmentandintroductionofnewservicesthataccompany

products.ThequalificationoftechnicalspecialistsusingeLearningandworksystemdesignas

partofmodernorganizationaldevelopmentroundsoffourspectrumofservices.

Our research and

development topics:

•Manufacturingtechnologies

• Productionmachinesand

systemmanagement

•Microproductiontechnology

• Stafftraining

» Ourmiss ion is tos ignif icant ly and last ingly

improvethecompet i t ivenessofourcustomers

withappl icat ion-specif ic modularandsystem

solut ions.«prof. dr. h. c. dr.-Ing. Eckart Uhlmann

PRODUCTION SYSTEMS

12 13

PRODUCTION SYSTEMSd I v I s I O N s

14 15

JOINING AND COATING TECHNOLOGY

» Newmater ia ls requirenewapproaches in

jo iningtechnology. Wedevelop innovat ivepro -

cessesforourpartnerswhichensurethere l i -

abi l i ty of their process ingchainandthe jo ined

components–regardlessofwhether inautomotive

construct ion, p lantconstruct ionorshipbui ld ing.

Wecanevendevelopeff ic ientprocessesforyour

p ipel ine!«prof. dr.-Ing. michael Rethmeier

Joiningandcoatingtechnologyranksamongthemostimportantstepswithinaprocesschain

inindustrysectorsandproductlines,comprisinginadditiontomaterialproductionalsothe

cycleoffabrication,operation,repairaswellasdisposalorrecyclingofaproduct.Thenewdivi-

sionJoiningandCoatingTechnologydevelopsinnovativeproceduresformaterialsthatprevi-

ouslycouldnoteasilybeprocessed.Particularlytheautomotiveindustryfacesgreatchallenges

duetotheincreasinguseofadvancedhigh-strengthandsuperhigh-strengthsteelvariantsand

steel-aluminumjoints.Thetypesofsteelmostrecentlydevelopedbysuppliershavenecessitated

newresearcheveninlong-establishedprocessessuchasresistancespotwelding.Simulationof

weldingprocesses,distortionsandresidualstressesspeedsuptheintroductionofcost-effective

andenergy-efficientprocessesinindustry.Anexcellentadditiontothisresearchintowelding

thinsheetsisarcwelding,evenatgreaterthicknesses.Applicationofnovelhigh-performance

arcweldingprocessesmakesjoiningofgreaterplatethicknesses,suchasthoseencounteredin

shipbuildingorpipeconstruction,particularlyattractivefromaneconomicpoint-of-view.

Our research and

development topics:

• High-performancearcwelding

• Resistanceweldingofsuper

high-strengthtypesofsteel

anddissimilarjoints

• Processoptimizationbymeans

ofweldingsimulation

• Applicationofmodernhigh-

powerjoiningprocesses,such

aslaserbeamandhybrid

welding

14 15

JOINING AND COATING TECHNOLOGY

d I v I s I O N s

16 17

TheAutomationTechnologydivisiondevelopsnewtechnologiesandsystemswhichcombine

innovativerobotics,controlandsecurityconceptswithmachinevisiontechniques.Itisour

goaltouseanintegrativecombinationofthesecorecompetenciestoincreasetheefficiency

ofprocessesforthebenefitofourcustomers.Oneexamplearemachiningprocesseswhich

canbeexecutedwithindustryrobotsinahighlyflexibleandcosteffectivemannerduetonew

methodsofforcecontrol.Furthermore,weuseinnovativeproductiontechnologymethodsand

automationconceptsinordertotapnewareasofapplicationandbusinesssegmentsinsecurity

technologyandmedicine.Ourproceduresforvirtualreconstructionofdocumentsaswellas

ourrobotsystemforrehabilitationofstrokepatientsarealreadybeingtriedandtested.

OurR&Dworkinprocessautomationandroboticsaimsatefficientuseofresources.Resource

efficiencyofhumanbeingsandautomationsystemsinchangeableproductionworkflowsis

enhancedbymeansofflexiblecooperationbetweenhumanandrobot.Inordertoincrease

energyefficiencywedevelopmethodsforintelligentinformationretrievalfromenergy-related

productiondata(energymining)aswellasforenergyefficiencycontrolling.Inaddition,based

onourexpertiseinimageprocessingandpatternrecognitionweopenupnewapplication

areas,especiallyformobiledetectionsystemsandforautomatedreconstructionofdocuments.

Ourcustomersalsobenefitfromourmanyyearsofexperienceinthefieldofautomatedoptical

qualitycontrol,supplementedbynewmethodsofrobotbasedtestingofmechanicalproduct

properties.

Our research and

development topics:

• Processautomationand

robotics

• Securitytechnology

• Processcontrolandsimulation

• Automaticopticaltesting

» Ourv is ion is human-centeredautomation, in

whichmanandmachinecanworktogetherc losely,

buta lsof lex ib ly .«prof. dr.-Ing. Jörg krüger

AUTOMATION TECHNOLOGY

16 17

AUTOMATION TECHNOLOGYd I v I s I O N s

18 19

Qualityofproductsandserviceshasbecomeastrategiccompetitivefactor.Notonlydevelop-

mentandproduction,butalsomanufacturingplanning,procurement,maintenance,distribu-

tion,aswellasaftersalesservicehavetobeconsidered.Theintentionofqualitymanagement

istotreatallqualityaspectsofacompany,includingitscustomerandsupplierrelations,in

acomprehensive,integratedmanner.Managingbothproductandprocessqualitytodayis

increasinglychallenginggiventheglobalizationofvaluechains.Tosuccessfullymasterglobal

competition,wesupportcompaniesbydevelopinginnovativeconcepts,methods,andorga-

nizationalapproachesforcontinuous,integratedassessmentandimplementationofquality

processesandqualitymanagementsystems.

Ourvisionis»qualityexcellence«,asustainable,excellentcorporatequalitywhichyieldsadded

valueforacompany,startingwithleadershipandstrategyqualitytoproductandprocessquali-

tyandtostructuralquality.Followingthisvision,wesystematicallyanalyze,evaluateandsecure

theeffectivenessandsustainabilityofqualitymanagementprocesses,methodsandsystems.

Thisway,wenotonlyassistourcustomersinsignificantlyimprovingtheactualandperceptual

qualityoftheirproductsandprocesses.Atthesametime,wehelptoreducemanufacturing,

deliveryandreclamationtimes,aswellasproductandprocesscosts.Inclosecooperationwe

providecustom-fitsolutionsfororganizational,methodicalandIT-relatedoptimizationofindi-

vidualqualityprocessesandsupporttheirimplementation.

Our research and

development topics:

• Integratedmanagement

systems

• Qualityplanningandrequire-

mentsmanagementaspart

oftheproductlifecycle

• Assessmentanddesignof

quality-aptvaluecreation,

LeanManagement

•Model-andsimulation-based

qualityandriskprotection

» Qual i ty hasthreedimensions: F i rst , qual i ty of

thestrategywithwhichproductsarebeingplaced

inthemarket; second,qual i ty of theproductsand

processesthemselves; th i rd, thestructural qual i ty

of methodsandorganizat ionestabl ished ina

company. Wesupport ourcustomers ina l l these

f ie lds. «prof. dr.-Ing. Roland Jochem

QUALITY MANAGEMENT

18 19

QUALITY MANAGEMENTd I v I s I O N s

20 21

»Wedevelop innovat ivesurgical ass istance

systemstogetherwiththeChar i této improvethe

safetyandeff ic iencyofoperat ions. Insomecases,

th is a l lowsustoprovidenewsurgical opt ionsfor

groupsofpat ientsforwhomtherapyhadnotyet

ex isted.«prof. dr.-Ing. Erwin keeve

TheFraunhoferIPKdivisionMedicalTechnologycooperatescloselywiththeCharitétodevelop

devicesforsurgicalintervention,especiallyforimage-controlledandminimallyinvasivesur-

gery.Innovationsinmedicaltechnologyaretodaycharacterizedbyahighdegreeofintegra-

tion.Imagingsystemsarecombinedwithinstrumentsforminimallyinvasivesurgerytoproduce

complextreatmentunits.Afocusofourresearchisdevelopingtechnologyforinterventional

therapy.Ouroverallgoalisensuringsurgicalinterventionscanbecarriedoutmoresafelyand

efficiently.

Onefocusisonthetechnicaldesign,developmentandclinicalevaluationofsystemsforimage-

guidedandminimallyinvasivesurgery.Additionally,wedevelopconceptsfortechnicalfeasibil-

ity,carryoutfeasibilitystudies,developprototypesandevaluatethelatterinpreliminaryclinical

applications.WefollowtheDINISOnorms9001:2000/13485:2003andconductapproval

processesaccordingtotheMedicalDevicesAct.Wearealsohappytofacilitatecontacttoclini-

calresearchgroups,professionalassociationsandhealthpolicybodies.

Our research and

development topics:

• Image-guidedandminimally

invasivesurgery

• Intraoperationalimagingand

interventionaltherapy

• Surgicalnavigationinstru-

mentsandcustomized

implants

• Qualityassurance,Medical

DevicesAct,andtheapproval

ofmedicaldevices

MEDICAL TECHNOLOGY

20 21

MEDICAL TECHNOLOGYd I v I s I O N s

22 23

TRANSLATING INTERDISCIPLINARY KNOW-HOW INTO TAILORED SOLUTIONSWehavebundledourknow-howintoanumberofdifferentcompetencecenters,defined

accordingtothetasksandchallengesofspecificindustrybranchesandmarkets.Thisallows

ustoofferourcustomersone-stopaccesstoourinstitute’sR&Dknow-how,whileensuring

theservicesprovidedarebothinterdisciplinaryandtailoredtospecificindustryconcerns.We

providecustomizedconsultingandsupportfortheintroductionofnewproducts,processesand

techniques.Furthermore,weworktogetherwithyoutoidentifypotentialandestablishnew

applicationareasforexistingproductsandtechnologies.Ourcustomershavetheuniqueop-

portunityofdevelopingandtestinginnovativetechnologies,demonstratorsandprototypesin-

dependentlyinanultra-modernenvironment.Wealsoprovideadditionalpresentation,training

andtransferservicesthatbenefitusers,manufacturersandresearchinstitutesinequalmeasure.

Our research and development topics:

• Benchmarking

• PDM/PLM

•Microproductiontechnology

• Cleaningtechnology

• Virtualreality

• Rapidprototyping

• Virtualproductcreationandproductionprocessdesign

• Toolandmoldconstruction

• Knowledgemanagement

c O m p E t E N c E c E N t E R s

22 23

24 25

OUR SERVICES

24 25

FraunhoferIPK’srangeofservicesassistscompaniesfrom

theinitialproductidea,tothedevelopment,planningand

creationofproducts,rightthroughtotherecyclingprocess.

Wedevelopnewtechnologiesinclosecollaborationwithour

customersandtesttheminthePTCexperimentalhallorat

thecustomersite.Wealsofacilitatetechnicalknow-howin

productiontechnologyanddevelopmethodsforimproving

organizationalmanagementofservices,production,quality

andenvironmentalmanagement.

Aspartofthis,weprovideawidespectrumofservices,includ-

ingbothmodularandsystemsolutions:

• Consulting(preliminarydiscussions)

• Feasibilitystudiesandprofitabilityanalysis

• Bilateralindustryprojectscomprisingallstages,including

prototypemanufacturing

• Projectplanningandengineering

• Developmentofprocesses,devicesandsoftwaresystems

• Systemtestingusingcutting-edgeequipment

• Supportfornationalandinternationalresearchanddevel-

opmentprojects

• Workshops,seminars,coaching

26 27

AswithallFraunhoferinstitutes,ourresearchfocusesonspe-

cifictasksandconcentratesongettingresults.Thepreliminary

researchwecarryoutonassignmentorwithfederal,Länder

orEUfundingisthenusedasthebasisofcontractresearch

forourcustomers.Ourworkingmethodsaredistinguishedby

highqualitystandards,professionalprojectmanagementand

ultra-modernlaboratoryequipment,whichsecureourcustom-

ersreliableresults.

FraunhoferIPKwascertifiedaccordingtoDINENISO

9001:2000inAugust2006.In2009itpassedthere-audit

accordingtoDINENISO9001:2008withflyingcolors.Weare

thusthefirstBerlin-basedproductionR&Dinstitutethaten-

suresqualityaccordingtotheindustrynormacrosstheboard.

»Tous,qualitymeanscustomerorientation.Improvingour

internalprocesseshasalastingimpactontheexcellenceof

ourresearchanddevelopment«,accordingtoProfessorEckart

Uhlmann,DirectorofFraunhoferIPK.

26 27

OUR APPROACH

28 29

OUR EXPERIENCE FOR YOUR SUCCESS

O U R c U s t O m E R s

Ourcustomersandpartnersarenationalandinternational

companies,publicinstitutionsandorganizations.Inaddition

toourR&Dinkeyareassuchasmechanicalengineeringand

equipmentassembly,machinetoolsandmoldconstruction,

automotives,aerospaceandelectronics,wecooperateon

projectswithITandhealth-careservicecompaniesandpublic

institutions.

Apartfromourcontractsforandwithmultinationalcorpora-

tions,acentralfocusisrealizinginnovative,cost-effective,

environmentallyfriendlytechnologieswithsmallandmedium-

sizeddevelopmentpartnersandsystemsuppliers.With

ourmanyyearsofexperienceinnationalandinternational

researchprojects,wecanhelpyoufindtherightproject

partners,obtainthird-partyfundingandcarryoutprojects,

includingatEUlevel.

28 29

TheFraunhoferGesellschaftistheleadingumbrellaorgani-

zationforappliedresearchinstitutesinEurope.Itpursues

contractresearchforindustry,theservicesectorandthe

government.Fullyrealizedsolutionstotechnicalandorganiza-

tionalproblemsaredevelopedquicklyandcost-effectivelyfor

businessesandothercustomers.TheFraunhoferGesellschaft

alsoparticipatesinindustryconsortiaaspartoftheEuropean

Union’stechnologyprograms.

Anadditionalimportantactivityisthestrategicresearchthat

FraunhoferGesellschaftconductsonbehalfofandfunded

byGermanfederalandLänderministriesandagencies.These

projectsresearchthetechnologiesoftomorrowandfindin-

novativesolutionstoissuesconcerningkeytechnologiesand

societyingeneral.

U N s E R E p A R t N E R

FRAUNHOFER GESELLSCHAFTTheFraunhoferGesellschaftcurrentlyhas59researchinsti-

tutesspreadover40sitesthroughouttheFederalRepublicof

Germany.Withapproximately17000employees,itboasts

anannualresearchbudgetofaround1.6billioneuros.Of

this,morethan1.3billioneurosisdedicatedtocontract

research,withtwo-thirdsgeneratedbyindustrycontractsand

government-fundedresearchprojects.Theremainingthirdis

contributedbythefederalandLändergovernmentstoallow

theinstitutestodevelopsolutionsforproblemsthatwillonly

becomerelevanttothemarketandsocietyinfivetotenyears.

FraunhoferGesellschaft,whichwasfoundedin1949andisan

accreditednon-profitorganization,includesamongitsmem-

bersrenownedcompaniesandprivatesponsors,whichhelp

shapeit’sresponsetochangingdevelopmentrequirements.

Theassociation’sheadquartersarebasedinMunich.

O U R p A R t N E R s

30 31

Wecooperatecloselyonapplication-orientedbasicresearch

withourpartnerintheProductionTechnologyCenter,the

InstituteforMachineToolsandFactoryManagement(IWF)at

theTechnischeUniversitätBerlin.Atitsfoundingin1904,the

IWFwasoneofGermany’sfirstinstitutionstoprovideproduc-

tiontechnologytrainingandresearch,andtheestablishment

ofitsproductiontechnologyexperimentalhallwasground-

breakingforthediscipline.TheIWF’sresearchandtraining

focusesonindustrialplanttechnologyandmanagementand

includesthedevelopmentofprocesstechnologies,production

equipment,andinformationtechnologymodeling.Approxi-

mately70scientistsworkonthe»digitalfactory«,conducting

interdisciplinaryresearchattheinstitute.Theyinvestigateand

interconnectproductdevelopment,manufacturingplanning

andproductionusinginformationtechnologytocompre-

hensivelysimulate,verifyandoptimizeproductcreationand

lifecycles.

IWF‘sresearchisdividedintosevenmainareas:

• Qualityscience

• Industrialinformationtechnology

• Machinetoolsandmanufacturingtechnology

• Joiningandcoatingtechnology

• Assemblytechnologyandfactorymanagement

• Industrialautomationtechnology

• Reliabilityofjoinedcomponents

AsaninstituteoftheTechnischeUniversitätBerlin,theIWF

trainsapproximately200studentsannuallyinmechanical

engineering.TheIWFalsoparticipatesintheMaster’scourse

GlobalProductionEngineering,whichisprimarilyconductedin

Englishandpreparesstudentsfromaroundtheworldforthe

challengesoftheglobalindustrialsociety.Theinternational

networkofteachingandresearchinstitutions,withwhichthe

IWFcooperates,alsocontributestothecourse.

IWF – INSTITUTE FOR MACHINE TOOLS AND FACTORY MANAGEMENT

O U R p A R t N E R s

������������������������ ��������������������� ���� ��������������������

30 31

Patientsdirectlybenefitfromcutting-edgescientificinsight

andtechnologyappliedattheteachinghospital.Thankstothe

practicalemphasisofitsmedicaltraining,italsoguarantees

thehighestqualityoftreatmentinyearstocome.Over

128000in-patientsandapproximatelyamillionout-patients

aretreatedannually.Complicatedmedicalproceduresarerou-

tine.TheCharitéstrivestoshapethelifesciencesofthefuture

tosecurepatientsthemaximumlevelofbenefit.

Inmedicaltechnology,wecollaboratewiththeDepartmentof

OralandMaxillofacialSurgeryatCharité–Universitätsmedizin

Berlin.AsoneofGermany’soldesthospitals,theCharitéhas

arichtraditionandistodayoneofEurope’slargestteaching

hospitals.Overits300yearsofhistory,includingeightNobel

Prizewinners,ithasgainedareputationforoutstandingmedi-

calresearchandtreatment,withmorethan14000employees

followingitsmotto»research,teaching,healing,helping«.

CHARITé – UNIVERSITäTSMEDIzIN BERLIN

32 33

BAM – FEDERAL INSTITUTE FOR MATERIALS RESEARCH AND TESTING TogetherwithBAM’sDivisionV.5»Safetyofjoinedcompo-

nents«,weresearchthesafetyandreliabilityofjoined

componentsandsystemsduringmanufacturingandopera-

tion.Evaluationoftheinteractionbetweenmaterial,process

andconstructionisakeypartofourworkhere.Thecentral

issueisclarifyinghotandcoldcrackingphenomenology.

Apartfromtestingcrackresistance,newhigh-performance

joiningprocesses,suchaslaserbeamandhybridweldingare

qualified,newalloyconceptsforweldingfillermaterialsare

developedforhigh-qualityjoiningofinnovativematerials.The

safetyandreliabilityofthejoinedcomponentsarenotonlyas-

sessedusinglaboratoryspecimens,butaboveallbyperform-

ingcomponentexperimentsandfull-scaletests.Weachieve

thisbyadaptingexistingtestproceduresandextendingnew

methods.Theresearchisbacked-upwiththeapplicationand

developmentofcorrespondingsimulationtechniques.

O U R p A R t N E R s

32 33

INNOVATION CLUSTERS – ACHIEVING SUCCESS THROUGH COOPERATIONTheFraunhoferinnovationclustersareatoolforspecificallyfosteringinnovationbymeansofcooperationintheregion.Allrel-

evantplayersintheprivatesector,science,governmentandsocietycooperateingeographicproximitytosuccessfullyactonthe

marketandthusalsopromoteandsecureemployment.FraunhoferIPKheadstwoinnovationclusters,»SecureIdentityBerlin-

Brandenburg«and»Maintenance,RepairandOverhaulinEnergyandTransportation«.

secure Identity – Uniqueness und Authenticity in the

Real and digital World

TheFraunhoferinnovationcluster»SecureIdentityBerlin-

Brandenburg»wasinitiatedNovember6th,2008.Theproject

isacollaborationbetweenfiveFraunhoferinstitutes,five

universities,12companies,aswellastheLänderBerlinand

Brandenburgalongwithindividualinstitutionsinotherfederal

states.Goalofthejointresearchanddevelopmentprojectsis

toprovidetechnologies,processesandproductsthatenable

theunambiguousverificationoftheidentityofindividu-

als,objectsandintellectualproperty.Suchidentitysecurity

ensuresthatidentitycanbeusedinmanydifferentwaysto

simplifyprocessesincommerce,administrationanddailylife.

Theapplicationsrangefromthenextgenerationoftamper-

proofpersonaldocuments,thesecurityofelectronicbusiness

processes,throughtocommunicationbetweenmachinesand

vehicles,andproductandbrandprotection.

(www.sichere-identitaet.de)

mRO – maintenance, Repair and Overhaul in Energy and

transportation

TheFraunhoferInnovationCluster»Maintenance,Repairand

OverhaulinEnergyandTransportation(MRO)«,begunin

2009,isworkingtowardsthedevelopmentandlong-termes-

tablishmentofresource-andenergy-efficientMROprocesses

andtechnologiesincities.MRO’simportanceforbusinessand

intheeconomyisincreasing.Asignificantproportionofcom-

panyreturnsaregeneratedbyafter-salesservicesforproducts

andgoodswithhighinvestmentcostsandlongdurability.This

isparticularlytrueoftheenergyandtransportationsectors,

whichhavealwayshadstrongrootsintheBerlin/Brandenburg

region.Largelyunforeseeablerepairsbecomenecessaryin

additiontoregularandscheduledservicingduringaproduct’s

lifecycle.Anoverhaulisabletonotonlyreturnaproducttoits

originalstate,butevenupgradeittothelatesttechnicaland

economicstandards.

(www.innovationscluster-mro.de)

Quelle:Siem

ensAG

F R A U N H O F E R I N N O v A t I O N c l U s t E R s A t I p k

34 35

• FraunhoferIPKhasastaffofapproximately240.

• TogetherwiththeInstituteforMachineToolsandFactory

Management(IWF)attheTechnischeUniversitätBerlin,

ouroffices,laboratoriesandexperimentalhallcovermore

than7100m².

• FraunhoferIPK’soverallbudgetin2009was

14.67million€,72percentofwhichwasself-financed.

Ofthis,approximately4million€wasgeneratedfrom

industrycontractsand5.4million€fromgovernment-

fundedprojects.

d A t E N U N d F A k t E N

FRAUNHOFER IPK IN FACTS AND FIGURES

34 35

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

[email protected]

director

Prof.Dr.h.c.Dr.-Ing.EckartUhlmann

corporate management

Prof.Dr.-Ing.KaiMertins

virtual product creation

Prof.Dr.-Ing.RainerStark

production systems

Prof.Dr.h.c.Dr.-Ing.EckartUhlmann

Joining and coating technology

Prof.Dr.-Ing.MichaelRethmeier

Automation technology

Prof.Dr.-Ing.JörgKrüger

Qualitätsmanagement

Prof.Dr.-Ing.RolandJochem

medical technology

Prof.Dr.-Ing.ErwinKeeve

Administration

HeikeKrieger

communications/marketing

SteffenPospischil

+493039006-100

+493039006-233

+493039006-243

+493039006-100

+49308104-1550

+493039006-183

+493039006-118

+493039006-120

+493039006-103

+493039006-140

YOUR CONTACT

36 37

s O F I N d E N s I E U N sH O W t O F I N d U s

DIRECTIONS

train

(fromBerlinMainStation)

• bytaxi(ca.10min.)

• takebus245frombusstop»LehrterStraße/Invaliden-

straße«directionS+UZoologischerGartentobusstop

»Franklinstraße«;travellingtimeabout20minutes.

Followroadfor200mandturnleftintoPascalstraße(ca.

5min.).

car

(arrivingfromdirectionHamburg,Rostock)

• A111toCharlottenburg(A100);A100toexitSpandau-

erDamm,turnleftontoSpandauerDamm,whichfurther

downbendsrightandisthencalledOtto-Suhr-Allee.

TurnleftintoCauerstraße.Furtherdowntheroadis

calledDovestraße,thenHelmholtzstraße.Turnleftinto

Morsestraße,whichfurtherdowniscalledPascalstraße.

(arrivingfromdirectionHannover,Leipzig,Nürnberg)

• A111toCharlottenburg(A100);A100toexit

Kaiserdamm,thenB2towardsTiergarten(Kaiserdamm,

thenBismarckstraße)untilLeibnitzstraße.Turnleftinto

Leibnitzstraße,whichfurtherdowniscalledCauerstraße.

StillfurtherdowntheroadiscalledDovestraße,then

Helmholtzstraße.TurnleftintoMorsestraße,which

furtherdowniscalledPascalstraße.

Airplane

(arrivingatBerlinTegel)

• TakebusX9directionS+UZoologischerGartentobus

stop»UErnst-Reuter-Platz«.Thenswitchtobus245,

directionNordbahnhof,tobusstop»Helmholtzstraße«.

Followroadfor200mandturnleftintoPascalstraße(ca.

5min.).

(arrivingatBerlinSchönefeld)

• bytaxi(40min.)

• takeregionaltrainRE7(directionDessau)tomainstation,

ortakeS9toOstkreuz,changetheretoS5,S7orS75

tomainstation.Fromthere,takebus245frombusstop

»LehrterStraße/Invalidenstraße«directionS+UZoolo-

gischerGartentobusstop»Franklinstraße«;travelling

timeabout20minutes.Followroadfor200mandturn

rightintoPascalstraße(ca.5min.).

36 37

IMPRINTFraunhofer Institute for

production systems and

design technology Ipk

pascalstraße 8-9

10587 Berlin

phone: +49 30 39006-140

fax: +49 30 39110-37

email: [email protected]

www.ipk.fraunhofer.de/en

director

prof. dr. h. c. dr.-Ing. Eckart Uhlmann

Editor

steffen pospischil

design

konstantin Heß

photo credits

gerold Baumhauer (1, 9, 12, 24)

Fraunhofer gesellschaft (27)

konstantin Heß (21, 34)

steffen pospischil (11, 14)