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Aluminum foam is a young lightweight structural material associated with energy-intensive production processes. To successfully establish the material and make its production future-proof, it is necessary to reduce energy consumption and improve...

Micropollutants such as BPA hinder plastic recycling and pose serious risks to ecosystems and human health. In the context of a circular economy, bioremediation was investigated as a recycling/upcycling approach, leveraging microbial BPA removal by...

This paper examines the use of surplus PV electricity by direct air capture (DAC) and polymer electrolyte membrane electrolysis. A techno-economic comparison of both technologies is carried out based on a mixed-integer linear programming...

Many serial process steps with tight manufacturing tolerances lead to high scrap rates in battery production. This paper presents approaches that enable the direct reuse of valuable cathode active material in the same batch. To this end, various...

High volatility requires flexible production systems. The ‘AutoPilot’ project developed a circular production cell concept combining physical modularity (e.g., wood veneer composites) with digital twins. Validation confirms increased...

Efficient climate protection is highly relevant given insufficient emission reductions and increasing economic challenges. The development of a methodology for identifying, economically and ecologically evaluating, and prioritising decarbonization...

Improving energy efficiency is gaining increasing importance in the context of the industrial energy transition. In particular, thermal processes offer untapped savings potential. Converting a hybrid chiller to direct current (DC) operation...

The study investigates the impact of low-fidelity strategies for hyperparameter optimization on the accuracy and computational costs of industrial load forecasting. Using a Taguchi design, two machine learning models were evaluated under different...

This article presents an approach that can be used for evaluating the potential of energy-related measures within PPC. To analyze conflicting targets of energy costs and logistical objectives, an energy model, a scheduling model, and a logistics...

This study serves as a basis for optimizing the batch mixing process in battery cell production. Based on the data collected, a clear correlation can be established between the energy consumption of the batch mixing unit and the viscosity of the...

The article presents a cross-technology, comparable modeling methodology as an end-to-end process for the efficient generation of efficiency curves from heterogeneous input data for agent-based energy system models. The proposed mathematical...

The increasing volatility of global markets, supply chain disruptions and disruptive events pose considerable challenges for manufacturing companies. Resilience – understood as the ability of organisations and networks to overcome crises, adapt,...

This paper presents a process chain for repurposing an automotive steering component. Specifically, the rack from an existing steering gear was extracted and reengineered into tie rods for a next-generation steering gear. This serves as a tangible...

The reduction of CO2-emissions is becoming increasingly important and is a key topic across all industrial sectors. Since steel is the most essential construction material in industrial application, CO2-reduced steels are gaining more attention....

Since 2011, Industry 4.0 stands for the vision of fully networked, intelligent production. However, around 15 years later, it is clear that German industry is still a long way from realizing this vision. This article examines the current maturity...

This article presents an LLM-based, adaptive assistance system for the diagnosis and repair of industrial machines. Free texts are cleaned up, categorized and transferred to curated fault trees. The system combines RAG with dialogue, assigns...

Predicting temperatures and residual stresses is essential in the glass tempering process. Classical numerical solvers are accurate but slow in large domains. This study develops a variant of a Multi-Input Fourier Neural Operator (MIFNO) as a fast...

Digital B2B platforms hold potential for platform owners and users, but are characterized by uncertainty, investment risks, and complex governance. In the IntWertL project, design principles for operating models for capital-limited, heterogeneous...

Factory planning is currently experiencing a major shift, marked by increasing uncertainty. In this context, four trend topics are widely discussed yet lack a clear industrial baseline: systematic risk management, a continuously updated factory...

Digital factory models offer significant potential for manufacturing. However, SMEs often fail to benefit because the required manual remodeling effort is prohibitive. This paper presents a method for the immediate utilization of point clouds, where...

The paper develops an integrated approach linking the energy value stream method to industrial energy system planning. First, it identifies process-specific opportunities to increase energy efficiency and derives suitable improvement measures. This...

This paper presents a hybrid sensor approach for automated rivet assembly that integrates drilling, sealing, and joining. Using laser triangulation and machine vision, setting depth and sealant wetting are validated in-process, substituting manual...

Wirebonding as a technology for producing electrical connections is characterized by numerous non-linear and mutually influencing process parameters. The developed random forest model was trained on 690 data points on different substrates and...

The article presents a marker-free track & trace solution for electrodes and other continuous materials. Identification based on the unique surface microstructure enables cross-process recognition and traceability of individual electrode...

This work extends DIN 276 by integrating factory elements and operational costs to enable a comprehensive lifecycle cost calculation. By combining DIN 276 with VDI 5200–4 and VDI 2067–1, a consistent basis for model-based, BIM-supported cost...

Operator neural networks open up new possibilities for the efficient modeling and simulation of complex industrial processes. This article provides an overview of common model types such as DeepONet, FNO, GNO, and related variants, and demonstrates...

The digitalization of manufacturing processes presents companies with the challenge of identifying and evaluating relevant smart services. Identifying and describing suitable smart services is particularly challenging, as many companies do not know...

With the digitization of industry, the volume of data is increasing significantly due to growing connectivity. Standardized data structures and interoperability are required for efficient use. This work uses administration shells and...