Research Projects
Current projects:
| Funding Agency | Federal Ministry for Economic Affairs and Energy – Bundesministerium für Wirtschaft und Energie (BMWE) Central Innovation Programme for small and medium-sized enterprises (SMEs) – Zentrales Innovationsprogramm Mittelstand (ZIM) |
| Period | 01.11.2024 – 31.10.2027 |
| Abstract | The aim of the “ChipConditioner” project is to develop application-specific fluidized bed reactors for the thermochemical conversion of powdered/particulate materials (chips, shavings) using flowing reaction gases. The preprocessor operates according to the fluidized bed process. It takes in magnesium chips (alternatively also aluminum or other materials) from above through a plastic pipe under the effect of gravity, suspends them with argon, degreases, dries, and heats the chips evenly with argon to a maximum of 200°C, and feeds them downwards into the main reactor via a screw conveyor or argon nozzles through the filling nozzle, where a partially liquid melt is produced for the casting process. For the specific process optimization required for various applications of the preprocessor, AI is being developed that enables largely automated optimization. |
| Funding Agency | Federal Ministry for Economic Affairs and Energy of Germany – Bundesministerium für Wirtschaft und Klimaschutz (BMWK) |
| Period | 01.04.2025 – 31.03.2028 |
| Abstract | The FlexE research project, carried out in cooperation between Promeos GmbH and Friedrich-Alexander University Erlangen-Nuremberg, aims to significantly reduce CO2 emissions in the casting industry by substituting natural gas with green hydrogen. This will be achieved by developing an innovative hydrogen fuel gas supply for porous burners, which will make heat supply more flexible on an industrial scale. During the development of hydrogen porous burners, Promeos identified the media supply as a key component critical to success. Both the geometry and the processes required to manufacture the geometry present technological hurdles. The core of the project is therefore the construction of various prototypes, which are manufactured using additive manufacturing processes and tested extensively for their performance, efficiency, and industrial integration capability. Computational fluid dynamics (CFD) plays an essential role in optimizing the prototypes by improving efficiency and burner characteristics through simulation of different designs under varying operating conditions. After development and testing, the optimal geometry and manufacturing process chain are selected. The validated technology is then implemented in an automated test rig for gravity casting, and the influence of hydrogen on the mechanical properties of the cast components is analyzed. These approaches lay the foundation for further innovations in the use of renewable energies and contribute to increased efficiency and reduced emissions in industrial combustion processes. |
| Funding Agency | German Research Foundation – Deutsche Forschungsgemeinschaft (DFG) |
| Period | 36 Months, Starting date unclear |
| Abstract | Mineral-bound and reusable molding materials for the casting production of aluminum components |
| Funding Agency | Federal Ministry for Economic Affairs and Energy of Germany – Bundesministerium für Wirtschaft und Klimaschutz (BMWK) Central Innovation Programme for small and medium-sized enterprises (SMEs) – Zentrales Innovationsprogramm Mittelstand (ZIM) |
| Period | Starting date unclear |
| Abstract | The project aims to develop a medium pressure die casting (MPDC) process that enables the cost-effective production of large-format components on smaller machines. The combination of numerical simulation, optimized process control, and new materials such as aluminum piston rods is intended to make the die casting process more efficient. In contrast to conventional die casting, where the melt is atomized upon entering the mold cavity and high holding pressures are required, in MPDC the component is filled with a compact free jet and compacted under reduced holding pressure. The approach takes into account the transient burst area and enables precise holding pressure control, reducing mold deformation and achieving low-burr casting. An aluminum rim for electric motorcycles is being manufactured as a demonstrator. The findings from the proposed project will enable the industry partner to use the MPDC process safely and reproducibly for a wide range of innovative, competitive products in existing and new market segments. |
| Funding Agency | Virtuelle Hochschule Bayern (vhb) |
| Period | 01.11.2025 – 30.06.2026 |
| Abstract | Using a casting application as an example, students learn how research findings from basic AI research can be transferred to engineering practice and facilitate everyday design tasks. The main focus is on teaching students the path from analyzing algorithms published in technical journals with associated open-source code to setting up virtual environments and application-oriented structural optimization. The knowledge is acquired as part of the ongoing VHB course “Data Acquisition, Processing and Analysis in Manufacturing Engineering and Materials Science” (DMM). Here, participants work on an interactive teaching example for the AI-supported design of lightweight construction tools. Students analyze load-dependent topologies, evaluate the results with FEM, and iteratively improve their designs. The aim is to combine research-oriented, virtual learning with an understanding of engineering transfer, thereby imparting critical judgment, digital tool competence, and AI-based optimization methods in a practical manner. Funding is being requested to develop an AI-supported exercise and integrate it into the ongoing VHB course DMM. |
Finalised projects:
| Funding Agency | German Research Foundation – Deutsche Forschungsgemeinschaft (DFG) |
| Period | March 2020 – February 2022 |
| Abstract | The primary objective of the project is to develop a methodology for the experimentally based design and incremental production of modular lightweight die casting tools. |
| Funding Agency | Central Innovation Programme for small and medium-sized enterprises (SMEs) – Zentrales Innovationsprogramm Mittelstand (ZIM) – Cooperation network |
| Period | 01.06.2023 – 31.05.2024 (Phase 1) |
| Abstract | The cooperation network develops processes and solutions that make production planning more efficient while maintaining consistent product quality and enabling energy- and resource-saving production. Tailored efficiency measures can significantly reduce the consumption of materials and primary energy in manufacturing. The entire casting process is optimized through the use of digital planning and process control tools. |