idw – Informationsdienst Wissenschaft
Nachrichten, Termine, Experten
Nachrichten, Termine, Experten
For the resource-conserving and, at the same time, economical production of plastic components, the utilization of intelligent, automated processes is crucial. At automatica 2025, the Fraunhofer Institute for Surface Engineering and Thin Films IST will be showcasing an innovative sensor system that records process data such as temperature and pressure in real time - directly in the tool. The wear-resistant thin-film sensors and the adoption of machine learning methods enable precise monitoring, automated quality assurance and sustainable optimization of the injection-molding process.
Real-time data acquisition through sensory tool inserts
Within the context of Industry 4.0, the precise recording and monitoring of relevant parameters, such as temperature and pressure curves in plastic injection molding, is essential. The Fraunhofer IST is presenting multifunctional thin-film sensors that are deposited directly onto the tool surface. These sensors enable spatially resolved real-time measurement of the temperature in the main stress zones of the injection-molding process.
One example is the thin-film sensor system, developed at the Fraunhofer IST, which was applied to an exchangeable tool insert. With 13 measuring points, it offers a comprehensive analysis of the flow front. The thermoresistive sensors are arranged in such a way that they precisely map the component geometry.
Machine learning for immediate process adjustments
Via a specially adapted electronic unit, the collected data are read out in real time and processed directly. With the aid of intelligent automation by means of machine learning algorithms on edge devices, it is possible to detect faults and weak points immediately. The component quality is reliably determined and is displayed as a color signal even before the mold is reopened following the injection process. As a result, corrections and adjustments can be swiftly implemented.
Sustainable materials and process monitoring
The high wear resistance of the thin-film system also enables the monitoring of processes with a high proportion of glass fibers and recyclates. This provides a significant contribution towards the utilization of sustainable materials in production operations within the framework of the circular economy.
At automatica 2025, you can discover how real-time data acquisition with sensor-equipped tool inserts actually works during the injection-molding process. Visit the Fraunhofer IST at the Fraunhofer joint stand in the Fraunhofer autoMOBILE Production Alliance area (Hall A4, Stand 319).
https://www.ist.fraunhofer.de/en/press-media/2025/innovative-thin-film-sensor-te...
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