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Faculty of Engineering Science

Chair Manufacturing and Remanufacturing Technology

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Research

Companies are facing new challenges due to increasing competition and globalization, rising energy prices and stricter environmental regulations.

​To benefit from this changing environment, companies need to analyze their strengths and weaknesses, develop new business models and product strategies to ensure a successful future for their business.

The Chair Manufacturing and Remanufacturing Technology supports you with a portfolio of expert knowledge in mechanical engineering, resource and energy efficiency, digitization, ergonomics, cleaning technology, green production systems, remanufacturing and manufacturing processes as well as logistics.

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Current research projectsHide

Project: AGILE COLLABORATION 4.0

Description: Against the background of the paradigm shift from rigid to agile structures, as it is necessary for Industry 4.0, among other things, companies face entirely new challenges. This is where the in-service training program Agile Collaboration 4.0 comes in. Agile Collaboration 4.0 qualifies Bavarian SMEs' employees for agile collaboration in the environment of Industry 4.0 with the help of overarching and interdisciplinary methodological knowledge.

An interdisciplinary team consisting of the Chair Manufacturing and Remanufacturing Technology, the Chair of Strategic Management and Organization, and the Campus Academy accompanies the project's implementation.

The continuing education measure is based on an in-service concept with a flexible learning process regarding time and place (blended learning).

The European Social Fund funds the project as part of Action 4, "Social Innovation". Therefore, participation in the training can be offered free of charge once during the project period for small and medium-sized enterprises (SMEs) from Bavaria.

Duration: 04.2020 - 12.2021

Project partner:  Campus Academy, Chair of Strategic Management and Organization, and numerous small and medium-sized enterprises from the northern Bavarian economy - from manufacturing companies to service providers and trading companies.

Contact person: M. A. Stefan Zeh (Phone: +49 (0)921 / 55-7374

Website: https://www.campus-akademie.uni-bayreuth.de/de/forschung/Projekt-Agile-Zusammenarbeit-4_0/index.html


Project: Development of design guidelines for the recycling-friendly design of battery systems in the context of the circular economy.

Description: Current lithium-ion battery systems are optimized specifically regarding to performance, energy density and costs. Aspects of a recycling friendly design of cells, modules and systems, in particular with regard to a function-preserving remanufacturing, have not been considered so far.

In view of the sharp increase in battery system-related material flows due to application in the growing electromobility market, the project aims to systemically analyse and derive design guidelines for recycling-friendly design in order to enable closed, efficient battery system cycles with low raw material losses.

Duration: 12.2020 - 11.2023

Project partner:  

  • TU Braunschweig

    Institute for Engineering Design (IK)
    Prof. Thomas Vietor

    Institute for Machine Tools and Production Technology (IWF)
    Prof. Christoph Herrmann

  •  Fraunhofer IKTS Dresden

    Fraunhofer Institute for Ceramic Technologies and Systems (IKTS)
    Prof. Mareike Wolter

  •  University of Bayreuth

    Chair of Electrical Energy Systems (EES)
    Prof. Michael Danzer

              Chair of Manufacturing and Remanufacturing Technology (LUP)
              Prof. Frank Döpper

Contact person: Dr. Bernd Rosemann, Jan Koller

Website:

BMBF - Batterieforschung in Deutschland
BMBF – Clusterprojekt GreenBatt/Redesign

Funding: Federal Ministry of Education and Research (BMBF)


Project: Digital Future Factory

Description: The in-service training Digital Future Factory is aimed at skilled workers and employees in the executive or first management level of manufacturing SMEs. It is intended to highlight opportunities that open up through innovative technologies and methods of digitalisation and to carry out an application-oriented knowledge transfer. An interdisciplinary team consisting of the Chair Manufacturing and Remanufacturing Technology and the Campus Academy for Continuing Education is supporting the implementation of the project. Digital Future Factory is based on a part-time concept with a flexible learning process in terms of time and place (blended learning). The contents of the ten modules are available here. More information on the conditions of participation can be found here.

The project is funded by the European Social Fund within the framework of Action 4 "Social Innovation".
Participation in the training can therefore be offered free of charge once during the project period for small and medium-sized enterprises (SMEs) from Bavaria. Interested companies should contact Mr. Julian Schmidt directly.

Duration: 04.2020 - 12.2021

Project Partners: Campus Academy as well as numerous small and medium-sized enterprises from the northern Bavarian economy - from manufacturing companies to service providers and trading companies

Contact: M. Sc. Julian Schmidt

Homepage: https://www.campus-akademie.uni-bayreuth.de/de/forschung/Projekt-Digital-Future-Factory/index.html


Project: D2ES2 (Flexible extruder and industry-grade control system for fused layer modeling (FLM) printers)

Description: In the subproject "Development of a flexible extruder with an automated nozzle change", an extruder is being developed that can extrude with different die geometries and process multiple materials during one manufacturing job. With this development, the manufacturing time should be reduced significantly (by about 80%), since it can be selected between build-up rate or accuracy, depending on the prerequisite. At the same time, the number of materials that can be processed is increased. The extruder can also be integrated into existing FLM-machines.

Duration: 01.07.2019 - 30.06.2021

Project Partners:

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)

Contact: Dr.-Ing. Joachim Kleylein-Feuerstein


Project: Efficient and Sustainable Production

Description: The project "Efficient and Sustainable Production" is designed to show employees in producing SMEs the opportunities that arise with efficient and sustainable production technologies and methods and to carry out an application-oriented knowledge transfer from university knowledge to industrial application. The objective is to systematically transfer user knowledge to the participants to make their own production both more efficient and more sustainable and to ensure rapid integration and implementation of imparted learning content in their own area of activity and responsibility.

The continuing education measure is based on an in-service concept with a flexible learning process in terms of time and place (blended learning).

The European Social Fund funds the project as part of action 6 "Networking activities between universities and companies". Therefore, participation in the training can be offered free of charge once during the project period for small and medium-sized enterprises (SMEs) from Bavaria.

Duration: 07.2021 to 12.2022

Partners: Campus Academy, as well as numerous small and medium-sized enterprises from the northern Bavarian economy - from manufacturing companies to service providers and trading companies.

Contact: M. A. Stefan Zeh (Phone: +49 (0)921 / 55 7374)

Website: https://www.campus-akademie.uni-bayreuth.de/de/zertifikatslehrgaenge/Effizient-und-nachhaltig-produzieren/index.html


Project: InnoInk (Development of an innovative Ink for the High Speed Sintering (HSS) process)

Description: The aim of the InnoInk research project is to develop an infrared-absorbing ink to increase both the productivity and resource efficiency of the HSS process.

Duration: 01.05.2020 - 30.04.2022

Partners: Sindlhauser Materials GmbH

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand) (Central Innovation Programme for small and medium-sized enterprises (SMEs))

Contact: M.Sc. Daniel Pezold


Project: InQCon

Description: The trend in lot sizes from high volumes towards higher product variance and smaller volumes is caused by shorter product life cycles. To stay profitable the used manufacturing technology has to be adjusted. Conventional 5-Axis-Milling-Centers are not ideal for this type of production due to the fact that their flexibility is bought with long programming and set up times. Opposed to this, 6 axis industrial robots provide such flexibility but can not reach the accuracies of conventional machines.

The aim of this project is to increase the robots necessary accuracies by means of sensors, actuators and the use of machine learning.

Duration: 01.07.2021 – 30.06.2023

Project partner:  

Contact person: M.Sc. Lukas Haas

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)


Project: KI-HUB Nordbayern

Description: In the project KI-HUB Nordbayern, a knowledge transfer network with blended learning is being created and established for the qualification of employees in SMEs on the topics of digitization and artificial intelligence (AI) to compensate for the shortage of skilled workers and reduce the impact of demographic change. The objective is to provide employees and managers in companies with practical methodological knowledge and to establish a knowledge transfer network. In the project, an in-service training concept with final certification is being developed free of charge and open to the public. By using the knowledge of technologies for the transfer of virtual and augmented content (mixed reality), completely new learning and teaching experiences can be generated and trained. This also results in significant added value especially in the case of the aging society and the resulting reduction in skilled workers. The knowledge transfer in SMEs has a significant influence on the efficiency and competitiveness of the companies - the project addresses this and thus achieves significant competitive advantages for SMEs.

Duration: 01.07.2021 - 31.12.2022

Project partner:  

Contact person: Dipl.-Ing. Tim Sokollek

Website: https://ki-hub-nordbayern.de


Project: LEGOLAS

Description: LEGOLAS (Air Extraction Efficiency Improvement in Electroplating - Optimized Airflow Using Blow-Off and Suction Devices) is concerned with research into the targeted, energy-efficient removal of electroplating fumes at the point of origin using a combination of blow-off and suction devices. The stated goal of the project is to significantly reduce the amount of energy wasted in the suction process, as well as to protect the employee from harmful or even toxic fumes.

Currently, mainly non-directional basin extraction systems are implemented in the form of edge extraction or by means of hoods above the basins. However, edge extraction systems are not able to ensure that no vapors escape from the pools, especially in the case of larger pools with a number of fixtures. Hoods have the disadvantage that they reduce accessibility to the basin and are therefore impractical. Targeted blow-off and suction devices, on the other hand, can drastically reduce escaping vapors. This leads to energy savings due to the significantly reduced air exchange rates in production halls and the resulting lower heating power required.

Duration: 01.07.2019 - 30.06.2021

Project partner:  

Contact person: M.Sc. Christoph Hoffmann (Phone: +49 (0)921 / 78516-328)

Funding: Bundesministerium für Bildung und Forschung - BMBF


Project: PräziMill (Development of a load-optimised solid carbide micro-radius milling cutter to stabilise the milling process)

Description: The aim of the research project PräziMill is to develop a load-optimised solid carbide micro-radius milling cutter to stabilise the milling process in 3D hard machining. This is necessary to reduce radial tool displacement, especially in solid carbide micro-radius cutters with a large length-to-diameter (L/D) ratio, and thus increase the manufacturing quality of workpieces.

The focus of the development is to optimise the tool geometry. To achieve this goal, simulation models are to be developed to investigate the static and dynamic behaviour as well as the chip flow. Based on the results, demonstrator tools will then be manufactured and tested on a laboratory scale and in industrial practice. The optimisation results are to be transferred to other milling tools after sucessful testing.

Duration: 01.05.2021 to 31.10.2022

Project partner: 

Contact person: M. Eng. Steffen Globisch

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)


Project: ReproStAF (Reduction of process-related support structures by increasing the thermal conductivity of the powder bed in additive manufacturing)

Description: The aim of the ReproStAF research project is to reduce the amount of required support structures by an average of 50% and the critical downskin angle from δ = 45° to δ = 15° by increasing the thermal conductivity of the powder bed during laser beam melting (LBM). This is aspired to by adapting the production machine and the production process. This increases productivity and material efficiency as well as geometric-constructive freedom in LBM. The development can be integrated into existing LBM production machines.

Duration: 01.04.2021 - 31.03.2023

Project partner:  

  • inkjet.parts (Jan Franck)

Contact person: M.Sc. Andreas Hofmann

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)


Project: SCoolS

Description: The demand for cooling applications for buildings and industrial processes is continuously increasing. To minimise their contribution to climate change is the widespread use of energy-efficient, sustainable cooling systems that do not contain climate-damaging substances necessary. The international cooperation project "SCoolS - Sustainable Cooling Systems" aims to increase the dissemination of sustainable cooling systems, especially among small and medium-sized enterprices. To this end, various cooling technologies are being investigated with regard to their performance and applicability, design and evaluation rules are being derived and a tool for selecting the most suitable cooling solution is being developed.

The complementary expertise of the international research partners allows a profitable consideration of fundamental commonalities and interdependencies of building and process cooling. In addition, the partners can make the findings and tools ideally available to the target group, especially small and medium-sized enterprices in Belgium and Germany. Numerous companies, e.g. from plastics processing and energy and cooling technology, are already involved in the project through the project committee.

Duration: 01.01.2019 - 31.12.2020

Project partner:  

  • Het Wetenschappelijk en Technisch Centrum vorr Bouwbedrijf (WTCB) (bbri.be, wtcb.be)
  • University Thomas More Kempen (thomasmore.be)
  •  South german plastic centre (SKZ-KFE gGmbH) (skz.de)
  •  University of Bayreuth, Chair manufacturing and remanufacturing technology (lup.uni-bayreuth.de)

And a project-accompanying committee made up of representatives from the energy and cooling technology sectors and the plastics industry.

Contact person: M.Sc. Christoph Hoffmann (Phone: +49 (0)921 / 78516-328)

Funding: IGF/AIF – Cornet (aif.de/index.php?id=260, cornet.online)


Project: Sens2IQ

Description: Residual moisture in electronic components so called Surface Mount Devices (SMD) can lead to defects during the reflow soldering process. Due to the high temperatures in the oven, the moisture vaporizes and expands abruptly. This expansion leads to popcorning, a disintegration of the parts with an audible crack. Moisture diffuses into the SMDs in atmospheres with a higher relative humidity than the storage conditions. Thus, the time in which SMDs can be processed is limited. At the moment, after surpassing the floor time, the components must be dried in an oven. The projects goal is to create a digital process model based on a residual moisture sensor. This sensor enables a demand-optimised incorporation of the cost and time intensive drying into the manufacturing process.

Duration: 15.01.2019 - 14.01.2022

Project partner:  

  • elektron Systeme und Komponenten GMBH & CO. KG

  •  SEHO Systems GmbH

  •  aDROP Feuchtemeßtechnik GmbH

  •  FAPS

  •  IPA

  • LUP

Contact person: M.Sc. Lukas Haas

Funding: Bayerisches Staatsministerium für Wirtschaft, Landesentwicklung und Energie – StMWi

Project Management Organisation: VDI/VDE-IT (https://vdivde-it.de/de)

Completed research projectsHide

Project: Oberfranken 4.0

Description: The project Oberfranken 4.0 of the University of Bayreuth supports small and medium-sized enterprises in the region of northern Bavaria with services for sustainable development and Industry 4.0 applications for manufacturing and logistics. To intensify know-how transfer from research institutions to companies an Industry 4.0 demonstration factory is implemented at the Chair Manufacturing and Remanufacturing Technology.

Duration: 04.2016 - 03.2020

Partners: Bergophor Futtermittelfabrik Dr. Berger GmbH & Co. KG, Eurofoam KFM GmbH, PEMA Vollkorn-Spezialitäten Heinrich Leupoldt KG, Pending System GmbH & Co. KG, PUTZIN Maschinenbau GmbH, WEDLICH.Servicegruppe GmbH & Co. KG, GAKO International GmbH, University of Applied Sciences Rosenheim, University of Bayreuth, Fraunhofer Project Group Process Innovation

Contact: Dr.-Ing. Stefan Freiberger, Dipl.-Ing. (FH) Joachim Kleylein-Feuerstein

Homepage: http://www.o4punkt0.de/


Project: empower

Description: The goal of the project “empower” is to develop an interdisciplinary concept for small and medium sized enterprises in Upper Franconia to improve energy efficiency of their production logistics. For this, a software tool for integrated decision support has been developed which is accessible online.

Duration: 09.2014 - 09.2016

Partners: Bergophor Futtermittelfabrik Dr. Berger GmbH & Co. KG, Eurofoam KFM GmbH, PEMA Vollkorn-Spezialitäten Heinrich Leupoldt KG, Pending System GmbH & Co. KG, PUTZIN Maschinenbau GmbH, WEDLICH.Servicegruppe GmbH & Co. KG, GAKO International GmbH, University of Applied Sciences Rosenheim, University of Bayreuth, Fraunhofer Project Group Process Innovation

Contact: Dr.-Ing. M.Eng. Dipl.-Ing. (FH) Oliver Oechsle, Dipl.-Wi.-Ing. Tom Drews, M.Sc. Paul Molenda

Homepage: https://empower.fh-rosenheim.de/


Project: RapidCfC – Development of Rapid Cores for Carbon

Description: The goal of the project RapidCfC is to apply 3D printing in the field of inner core production for CFRP products (CFRP: carbon fiber reinforced plastics). Due to the design possibilities and automated production processes in 3D printing a competitive advantage for applicants can be generated.

Duration: 03.2015 - 03.2017

Partners: HS 42 GmbH, Mayr Faserverbundtechnik GmbH, University of Bayreuth

Contact: Dipl.-Ing. Markus Kafara

Homepage: http://www.rapidcfc.uni-bayreuth.de/de/index.html


Project: Development of CFRP frame structure for helicopters of the ultralight class

Description: The goal of this project is to develop an innovative frame structure for helicopters of the ultralight class based on carbon fiber reinforced plastics (CFRP) to accomplish special needs of the aerospace industry, e.g. reduction of weight, reduction of emissions, extension of range, etc.

Duration: 04.2015 – 05.2017

Partners: CG TEC GmbH, ZCK Zuschnittcenter, Faserverbundtechnik GmbH & Co. KG, University of Bayreuth

Contact: M.Sc. Melanie Klein


Project: Development of network-based knowledge transfer to support implementation of a sustainable energy management system to increase energy efficiency in small and medium-sized enterprises

Description: In cooperation with numerous small and medium-sized enterprises a web-based tool for efficient knowledge-transfer, considering the specific requirements of small and medium-sized enterprises, to increase energy efficiency is developed. In this way, the web-based learning concept offers new possibilities for employees of industrial companies to have access to easy-to-use and flexible learning modules. Therefore, knowledge transfer from applied sciences to companies is strengthened.

Duration: 09.2015 - 11.2017

Partners: numerous small and medium-sized enterprises, e.g. Pass Stanztechnik AG, FECOM Maschinenbau GmbH, Friedrich Richter Messwerkzeugfabrik GmbH und Co. KG, Vogler Engineering GmbH, etc., University of Bayreuth

Contact: Dr.-Ing. Stefan Freiberger, Dipl.-Ing. Thomas H.-J. Uhlemann

Press release: http://www.uni-bayreuth.de/de/universitaet/presse/pressemitteilungen/2015/182-Uni-Bayreuth_-Ingenieure-entwickeln-kostenloses-Wissensnetzwerk-fuer-bayerische-Unternehmen-fuer-ein-nachhaltiges-Energiemanagement/index.html


Project: GlacioCut (high-performance circular saw blades for machining frozen wood)

Description: The aim of this research project is to develop a high-performance circular saw blade for the industrial processing of frozen wood. Through its application, the resource efficiency of the process is to be increased.

Duration: 01.10.2019 until 31.12.2020

Project partner:  

  • Gelo Holzwerke GmbH

  •  Kohnle GmbH

Contact person: M.Sc. Julian Schmidt

Funding: ZIM (Central Innovation Programme for SMEs)


Project: EMLIC

Description: The aim of the EMLIC research project is to increase both the productivity and the resource efficiency of metal cutting processes. To this end, lightweight construction technologies are to be transferred to a milling tool.

Duration: 01.06.2019 - 30.11.2020

Project partner:  

  • Maier GmbH

Contact person: M.Sc. Benjamin Thorenz, Dipl.-Ing. Markus Friedrich

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)

Homepage: https://www.campus-akademie.uni-bayreuth.de/de/forschung/Projekt-Digital-Future-Factory/index.html


Project: LEiA

Description: With the LEiA (Lightweight Efficiency in Additive Manufacturing) project, the aim is to increase the energy efficiency and process speed while simultaneously taking into account component quality and the economic efficiency of an additive manufacturing system that uses the extrusion process (also known as fused layer modeling (FLM)). According to the current state of the art, an increase in build rate is always accompanied by a reduction in accuracy. This situation is to be countered both by reducing the moving masses of the system and by implementing measures to increase energy efficiency, especially by redesigning the heating system. The developed components are to be used in new systems as well as retrofitted to existing systems.

Duration: 01.10.2019 - 31.12.2020

Project partner:

Funding: ZIM (Zentrales Innovationsprogramm Mittelstand)

Contact person: Dr.-Ing. Joachim Kleylein-Feuerstein


Project: Application Center 3D Printing Upper Franconia

Description: Additive manufacturing offers outstanding potentials and diverse application possibilities, which are not yet tangible and qualifiable for many companies. Often, the process specific potentials and challenges associated with the characteristic material properties are not sufficiently known in the companies. The aim of the project Application Center 3D Printing Upper Franconia is to build up specific know-how in your company.

In general this know-how is built up by organizing seminars on additive manufacturing and on specific topics such as polymer-based additive manufacturing, quality assurance and occupational safety. In addition, best-practice examples are developed with the partners of the Application Center 3D Printing Upper Franconia through case studies. These case studies are showing how additive manufacturing can be applied  effectively and sustainably at companies.

Duration: 01.10.2017 - 30.06.2021

Funding: European Union via The European Fund for Regional Development (EFRE) and The Upper Franconian Trust (Oberfrankenstiftung)

Contact: ​M.Sc. Christian Bay

Website: www.3dfranken.de


Project: Roadmap flex Pro

Description: Coburg University of applied sciences and arts and University of Bayreuth work together to offer insight into newest technologies mainly for small and medium sized enterprises (SME). Aim of the project Roadmap flexPro is to transfer know-how about current technologies from the universities to companies in northern Bavaria. As this project is funded by the European Fund for Regional Development by the European Union it is free of cost for the participating companies. The showcased technologies shall enable companies to produce highly individual products with flexible production assets. These solutions are presented in workshops and in different fully functional prototype to give the companies a direct experience of the benefits of these technologies.

Duration: 03.2018 - 08.2021

Partners: Further Information on the participating companies, the showcased technologies and on the Roadmap can be found on our project homepage.

Contact: Dipl.-Ing. Falko Künkel

Homepage: https://roadmap-flexpro.de/


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