Fraunhofer Institute for Production Technology IPTResearch project "DigiGlas"
In Germany, subtractive grinding and polishing processes are usually used for the production of high-precision glass lenses. These methods are very cost-intensive due to the low level of automation, especially for complex geometries. The processes are also not environmentally friendly due to the use of many harmful operating materials and material removal of up to 90%.
In Asia, especially in China, where simpler geometries are primarily manufactured, molding processes are used predominantly. Molding is economically more attractive for mass production and leads to much less material loss compared to grinding. In Germany, where the focus is mostly on more complex geometries, glass molding is not yet well established. The process development is currently mainly experienced-based. This trial-and-error approach makes production uneconomically expensive as several hundred trials are often necessary to find the optimum process parameters.
Digital model optimizes process chain for optics production
The "DigiGlas" research project aims to make optics production more efficient through molding: With the help of AI models and simulations, production processes are optimized, making manufacturing significantly more resource-efficient and economical.
The AI models enable demand-driven process development and take factors such as energy, time, and accuracy into account. They are also able to forecast maintenance intervals and quality predictions. At the same time, a hybrid model is being developed that combines AI methods and FEM simulation to increase the prediction accuracy of the glass molding process and thus improve the efficiency and quality of production.
Compared to conventional grinding and polishing, the digitally optimized process will save up to 90% material and reduce waste. Another goal is to significantly reduce CO2 emissions in the production of aspheric lenses. This amounts to an average of around 22 kg CO2 per lens in conventional manufacturing processes and is to be reduced to less than 3 kg CO2.
Further development of technology for new systems and applications
The digital models developed in the project can be flexibly applied to different systems and form the basis for "Software as a Service" (SaaS). This service makes it possible to develop new products efficiently, even with less experience. It also creates the basis for future digitalization and AI research projects that support further process optimizations.
In addition, a concept for digital business models is being developed that specifically promotes the sale and application of the innovation. In this way, the project is making an important contribution to the spread of energy- and resource-saving molding processes.
By setting up a powerful server structure and a digital platform, new developments can be implemented directly in Aachen and the Rhenish mining area. The continuous further development of the digital modules and software by the project partners ensures that customers benefit from production systems in the long term.
Project partners
- Vitrum Technologies GmbH, Aachen (coordination)
- Fraunhofer Institute for Production Technology IPT
Project sponsor
VDI Technologiezentrum GmbH
Funding
The DigiGlas project is funded by the German Federal Ministry for the Environment, Nature Conservation, Nuclear Safety and Consumer Protection (BMUV) as part of the DigiRess II funding program.
Funding reference: 13DRN03B