Research Projects
Current projects:
| DigiGuss – ChipConditioner / Setting up a test rig to investigate the processor operating principle and data generation, as well as material evaluation in casting processes |
| Funding Agency | Federal Ministry for Economic Affairs and Energy – Bundesministerium für Wirtschaft und Energie (BMWE) |
| Funding program | Central Innovation Programme for small and medium-sized enterprises (SMEs) – Innovation Networks / Zentrales Innovationsprogramm Mittelstand (ZIM) – Innovationsnetzwerke |
| Funding reference number | 16KN118822 |
| 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. |
| FlexE – Joint project: Development of a hydrogen fuel supply to reduce CO2 emissions by making the energy source more flexible (FlexE) Subproject: Development of an innovative hydrogen fuel supply for porous burners |
| Funding Agency | Federal Ministry for Economic Affairs and Energy of Germany – Bundesministerium für Wirtschaft und Klimaschutz (BMWK) |
| Funding program | 7th Energy Research Program of the Federal Government – 7. Energieforschungsprogramm der Bundesregierung |
| Funding reference number | 03EN2125A |
| 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. |
| Mineral-bound and reusable molding materials for the casting production of aluminum components |
| Funding Agency | German Research Foundation – Deutsche Forschungsgemeinschaft (DFG) |
| Funding program | Individual Research Grants – Sachbeihilfe |
| Funding reference number | MU 4410/4-1 |
| Period | 01.01.2026 – 31.12.2028 |
| Abstract | The project investigates mineral-bound molding materials as innovative, reusable permanent molds in light metal casting. The use of ultra-high-performance concretes and alkali-activated binders is intended to reduce the reactivity and thermal conductivity of conventional metal molds and improve process stability. In addition to optimizing thermal and mechanical properties, different aggregates and fiber additives are being investigated to further increase the durability of the mold materials. Experimental studies and numerical simulations provide the basis for an in-depth understanding of mold filling, stress distribution, and the service life of concrete molds. In addition, the influence on the microstructure and mechanical properties of selected aluminum alloys is being analyzed in order to be able to specifically adjust the process parameters. The aim is to develop a cost-efficient, resource-saving casting process that bridges the gap between sand casting and permanent mold casting and opens up new potential for industrial applications. |
| Development of a pressure-reduced die casting process for the economical production of large-format components with limited machine sizes (MPDC) Subproject: Development of a novel pressure-reduced die casting process with a focus on numerical optimization and fundamental casting tests for methodological description with the aim of cross-component transferability and reproducibility |
| Funding Agency | Federal Ministry for Economic Affairs and Energy of Germany – Bundesministerium für Wirtschaft und Klimaschutz (BMWK) |
| Funding program | Central Innovation Programme for small and medium-sized enterprises (SMEs) – R&D cooperation project / Zentrales Innovationsprogramm Mittelstand (ZIM) – FuE-Kooperationsprojekt |
| Funding reference number | KK5059925SH4 |
| Period | 01.01.2026 – 29.02.2028 |
| Abstract | The project aims to develop a medium pressure die casting (MPDC) process that enables the cost-efficient 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. |
| KI meets vhb: Testing AI application scenarios in the online course “Data Acquisition, Processing and Analysis in Manufacturing Engineering and Materials Science” |
| Funding Agency | Virtuelle Hochschule Bayern (vhb) |
| Funding program | KI meets vhb: Enabling experimental approaches in online teaching |
| Funding reference number | Kl_25-II_23-ll-03-14Mue1_23-ll-03-14Mue2 |
| 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:
| Design, analysis, and demonstration of the principles of incrementally manufactured, modular lightweight die casting tools |
| Funding Agency | German Research Foundation – Deutsche Forschungsgemeinschaft (DFG) |
| Funding program | Individual Research Grants – Sachbeihilfe |
| Funding reference number | MU 4410/2-1 |
| Period | 01.06.2020 – 31.01.2024 |
| 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. |
| Digitalization and resource efficiency in the casting industry (DigiGuss) |
| Funding Agency | Federal Ministry for Economic Affairs and Energy of Germany -Bundesministerium für Wirtschaft und Klimaschutz (BMWK) |
| Funding program | Central Innovation Programme for small and medium-sized enterprises (SMEs) – Cooperation network / Zentrales Innovationsprogramm Mittelstand (ZIM) – Kooperationsnetzwerk |
| Funding reference number | 16KN118801 |
| 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. |