idw – Informationsdienst Wissenschaft
Nachrichten, Termine, Experten
Nachrichten, Termine, Experten
idw - Informationsdienst
Wissenschaft
New simulation approaches from the Fraunhofer IST aim to improve the interaction between simulation and practice
Whether in vacuum coating or water treatment, simulations are indispensable tools for research and development. They make it possible to reduce the number of physical tests, configure processes more efficiently and save valuable resources. Until now, however, their utilization has generally been reserved for specialized experts. The Fraunhofer Institute for Surface Engineering and Thin Films IST is going to fundamentally change this - with a new approach that takes simulation out of the expert niche and transfers it directly into industrial practice.
Simulation for everyone: from black box to toolbox
“We want to bring the simulation out of the sole domain of experts and integrate it directly into practical development,” explained Dr. Dennis Barton, Team Leader Simulation at the Fraunhofer IST. The aim is to provide people from design and development with a sound basis for decision-making - without the need to acquire in-depth knowledge of the complexity of numerical modeling.
The institute is using an in-house developed PICMC/DSMC solver – which is well established in the expert community – to simulate low-pressure plasmas and gas flows in PVD coating processes. The models provide important information on gas-separation factors, target erosion and coating-thickness profiles. This is supplemented by methods such as computational fluid dynamics (CFD), which are used, for example, in the design of electrolyte reactors or dryer constructions.
The next step: data-driven modeling and AI
In the future, the Fraunhofer IST wants to further simplify access to simulation methods - with a growing team, intelligent data strategies and the integration of artificial intelligence. Machine learning methods and large language models will thereby help to make simulation-based decisions accessible to non-experts. In this context, a key role is played by digital twins, systematic data management and networked sensor technology.
Systematic support for young talent
The institute is also keeping an eye on the nurturing of future specialists. In his course ‘Modeling Methods in Surface Technology’ at the Technische Universität Braunschweig, Dr. Barton teaches the necessary skills: “In simulation, you need your own mindset - an understanding of when a model is good enough, what computing capacities are available and how results can be compared with reality.”
With its new simulation approach, the Fraunhofer IST is providing an important contribution towards the digitalization and sustainability of industrial processes - and is simultaneously paving the way for a broader, practical utilization of modern simulation technologies.
https://www.ist.fraunhofer.de/en/press-media/2025/digital-tools-for-industrial-p...
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