Hochschule KarlsruheHochschule Karlsruhe - University of Applied Sciences
Hochschule KarlsruheHochschule Karlsruhe - University of Applied Sciences
Machine boring holes in a component, sparks flying

Institute of Materials and Processes

Profile Projects

Current research projects

simulation model of value stream kinematics

Value Stream Kinematics

Vision of value stream kinematics: Covering value streams with one kinematics.
The properties can be positively influenced by selective coupling of individual kinematics:

  • greater stiffness
  • greater accuracy
  • greater flexibility

This makes it possible to achieve both high process forces and high accuracies with the same flexible kinematics.

The project is part of a Future Field of KIT. The IMP is responsible for creating a simulation model of the system.

You can find more information at http://wertstromkinematik.de/

reference of funding by Federal Ministry of Economic Affairs and Energy


For this research project, the resulting stresses in 3D printed components will be calculated based on a temperature simulation. The simulation is based on the machine path and represents an exact replica of the real process. Based on the data, known problems can be avoided by early detection before the printing process. Furthermore, the results are to be used, for example, to identify critical geometries using artificial intelligence. In this way, problems can be rectified by the algorithm during operation without the need for simulation.


several components

Graphite processing

Development of a system for processing waste from isostatically pressed graphite for use as secondary graphite in electrical discharge machining (EDM)

  • Crushing of used graphite electrodes from die-sink erosion
  • Drying of oily graphite granules
  • Pulverization of graphite granules
  • Binding and pressing of graphite dusts to secondary graphite
  • Milling of secondary graphite and erosion with the newly produced secondary electrodes
reference of funding by Federal Ministry for Economic Affairs and Energy


Adaptive process control unit for lubricant dosing

The aim of this project is to use artificial intelligence methods to generate models that can reliably predict the applied lubricating grease mass based on process parameters. In addition to this, characteristic grease parameters for the classification of the grease status are to be predicted based on measured values. Finally, it should be possible to predict the necessary adjustment parameters to enter a lubricating grease mass range.

schematic drawing of a foam structure

InSeL 2

Innovative foam structures for efficient lightweight construction 2 (InSeL)

Inter-university project to address scientific and technological issues with regard to:

  • material selection
  • material combination
  • material treatment
  • production, machining and processing
reference of funding by Federal Ministry for Economic Affairs and Energy

Increasing the productivity of the electro-erosive drill

Increasing the productivity of the electro-erosive drill by selective contamination of the dielectric with metallic particles


 reference of funding by Federal Ministry for Economic Affairs and Energy

Breathing mask

The aim of this research project is to develop a filter fleece for a breathing mask that is particularly effective against viruses and bacteria. To achieve this effect, the fleece is equipped with a triple barrier.

  • biological barrier
  • chemical barrier
  • physical barrier
 reference of funding by Federal Ministry for Economic Affairs and Energy


The core objective of the project is the development of a calculation tool for the simple determination of control surface loads on small aircraft. For this purpose, different geometries and flow situations are investigated by means of CFD and in the wind tunnel. The results obtained are used to develop a calculation method for quickly and reliably calculating the forces occurring on arbitrarily designed control surfaces. Subsequently, the software based on this method will be validated by means of flight tests with different aircraft types. In addition, a method for verifying the calculated loads using the control forces measured in flight will be developed.


drawing of robot on mobile platform


Articulated robots on mobile platforms offer the potential to meet increasing flexibility requirements of modern manufacturing systems. In the development of these platforms, a fundamental mechanical problem exists between the workspace and the center of gravity. The project investigates how the operating range of a mobile robot with robotic arm can be increased by stabilization strategies.

  • determine static and dynamic forces in the system
  • tilt detection & active tilt stabilization strategies
  • control approaches for robot control taking into account the risk of tilting

Subproject "Stabilrobot" was funded by the state of BaWü in the framework of the call for innovative projects

cutoff of evaporator


To ensure reliability in miniaturized devices or processes with increased heat flows, more and more efficient cooling methods have to be used to cope with the decreasing available cooling surfaces. The goal is to cool high heat flux densities with vortex-generating geometries.

  • Development of a special evaporator/heat exchanger
  • Refrigerant is extracted in a helical geometry (swirl flow)
    • Centrifugal acceleration of the refrigerant against the hot wall leads to an increase of the critical heat flux by up to 40%

More heat can be dissipated with the same surface area / available installation space. This allows a wide range of technical applications.

 reference of funding by Federal Ministry for Economic Affairs and Energy

Smart Air

Novel, smart module for house air conditioning based on adsorption

  • Adsorber material dries air analogous to sponge, can be dry or absorbed with water
  • Regeneration by means of contact heating PTCs
  • Adsorption and desorption cycles are controlled by smart control algorithm
  • Significant increase in efficiency compared to conventional systems

Completed research projects

printer printing thermoplastic component

Smart Printbed

Thermal management is crucial in the processing of high-performance thermoplastics.

When printing high-performance polymers such as PEEK, stresses occur in the component due to the relatively high printing temperature and changes in the material structure. These stresses can lead to micro-cracking, warping, cracking and ultimately component failure. In the Smart Printbed project, a system was developed to minimize these influences and also save electrical energy.

 reference of funding by Federal Ministry for Economic Affairs and Energy

ZPTA tool

The aim of the project was to develop an all-ceramic milling tool made of zirconia and plate-reinforced aluminum oxide for the finishing of nickel-based alloys. For the project, the cutting edge geometry was designed, simulated and tested in milling trials. This iterative cycle was run several times to achieve an optimal cutting edge geometry.


 reference of funding by Federal Ministry for Economic Affairs and Energy

Flow rate control for electro-erosive drilling machining

  • Investigation of the influence of flow rate (flushing) on the target engineering variables in electro-erosive drilling
  • Development of a model equation for a process-favorable flow rate as a function of the machining conditions
  • Ensuring productivity and process stability
 reference of funding by Federal Ministry for Economic Affairs and Energy

Low-damage drilling erosion

  • Electro-erosive drilling machining
  • Investigating the influence of machine parameters and dielectrics on edge zone damage
  • Macro- and microscopic analysis of edge zone damage on nickel-based alloys
  • Elaboration of parameter combinations for minimization of edge zone damage
research team standing around project rollup in front of HKA building


Inter-university project on innovative foam structures for efficient lightweight construction (InSeL)

Research question: "What are the potential applications of metallic foams as modern lightweight materials?”

  • Materials engineering
  • Surface technology
  • Necessary process modeling


 reference of funding by Federal Ministry for Economic Affairs and Energy

Gas Pig

Development of an innovative drive system for acoustic-measuring leak detection pigs when used as a single-pig system with dry-running mode in gas pipelines without elasto-hydrodynamic lubrication film by pig hoists.

  • Numerical design of the chassis and elaboration of the drive concept
  • Development of test environments for leakage detection
  • Strategy for acoustic leakage detection
 reference of funding by Federal Ministry for Economic Affairs and Energy


Flexible clamping system with integrated measuring device for 3D printing for the production of hybrid components

  • Enables components to be re-clamped several times during 3D printing 
  • Electrical clamping device enables the component to be fixed in any desired position
  • Shape of the component is scanned by the clamping mechanism during clamping
  • Matching with CAD model to automatically detect object and its position in space and identify printing plane

The information of the positions of each clamping pin is evaluated by a micro-controller. The control of the 3D printer is adapted to print on inclined planes.

 reference of funding by Federal Ministry for Economic Affairs and Energy

Electro-erosive drilling machining of titanium alloys

  • Development of parameter technologies for the electro-erosive drilling machining of titanium alloys
  • Investigation of process-related edge zone damage
 reference of funding by Federal Ministry for Economic Affairs and Energy


In this research project, a tabletop rotary microtome will be developed that allows histological sections of multiple tissue samples to be cut simultaneously in an oversized kerosene block. A method for semi-automatic further processing of the specimen is designed to enable the difficult handling of the section, which is only a few µm thick.


 reference of funding by Federal Ministry for Economic Affairs and Energy

Process optimization of electro-erosive drilling

Production of defined bore diameters

  • Developing a parameter solution field for the electro-erosive production of bores with defined diameter
  • Analyzing productivity as a function of machining conditions
  • Deducing user recommendations
 reference of funding by Federal Ministry for Economic Affairs and Energy

Machine benchmark for die-sinking EDM systems

  • Investigation of the performance of different die-sinking EDM systems
  • Use of different, complex electrode geometry (cavity, multiple ribs, filigree webs)
schematic drawing of a crane


The design of the load moment limiter (LMB) of mobile cranes is only done with inaccurate known / unknown system parameters and a purely static consideration of the crane behavior. Dynamic modeling of mobile working cranes offers the potential for increasing the performance of the LMB.

  • Modeling of a multi-body model of the crane replacement system
  • Developing methods for parameter optimization
  • Application of selected method to detailed model of mobile working crane
  • Comparison (improvement, if necessary) of the load moment limitation.

The project was funded by the state of BaWü in the framework of the call for innovative projects.

BEMT logo


BEMT: Blended Entrepreneurial and Manufacturing Technology; funded within the Erasmus+ Key Action 2 program of the EU, completed in October 2018, the courses created within the project can be found at the BEMT website.

The aim of the project is to develop a new line of small-business owners with engineering background grasping in-depth knowledge and expertise in manufacturing technology with adequate entrepreneurship skills capable of establishing a sustainable small metal manufacturing business that falls under the micro economy spectrum and who are capable of establishing successful and profitable business relationships with large enterprises in Egypt and the open market in general as a feeding/end-user products  industry with competitive production quality.

Publications Team Facilities Directions