Vision and Goals

Individualization of Mass-Produced Components in one Production Line

Following the markets’ trends for ...

• Reduction of batch sizes with simultaneous increase in product variety,
• Individualization possibilities of the product geometry beyond the software-based customization,
• Smart products with integrated aquisition, processing and communication of (big) data,
• Efficient utilization of highly innovative functional materials by printing,

... the lighthouse project pursues the vision to expand existing production lines with digital functionalization and customization technologies, allowing the manufacturing of customized products in mass production environments.

This vision became reality. Electronic functionalities such as conductor paths, sensors and lighting elements can be integrated into products by digital print and laser technologies, exactly where the customer wants them. Digital printing processes help to apply functional materials such as conductive pastes or photo polymers directly onto two- and three-dimensional surfaces of lightweight components. Laser processes subsequently sinter or cure these printed structures and components locally to make the printed materials functional (in this case electrically conductive). This selective application of materials, in which, according to additive technology, material is only applied where it is needed, is remarkably resource and environmentally friendly. The application of digital manufacturing processes enables the cost-effective and standardized production of components and products within a mass production line, where the digital methods are integrated into the manufacturing process and individualize the products.

The aim of the project was the development of new technologies for a resource-saving, cost-efficient individualization of mass products.

This is based on digital material application and removal processes and their integration into existing highly efficient mass production lines.

Hence, lot sizes up to one are to be realized by the integration of digital printing and laser technologies.

Now in the fourth year of the project, priority is on topics related to process stability of digital printing and laser technologies as well as component reliability. Specifically, this involves:

• Research and development of control concepts of digital prining and laser technologies for apllications in industrial environments
  
• Research and development of reliable assembly and connection techniques for printed structures and electronic components (connectors, SMD components, wiring, moduls, ...) as well as reliability assessments of the network using functional examples from the automotive, aviation and illumination sectors.