Center of Device Development CeDeD
Center of Device Development CeDeD
Development of new technical glasses using a robot-controlled process line for automated glass development
© Fraunhofer ISC
Development of new technical glasses using a robot-controlled process line for automated glass development

© Fraunhofer ISC

Fully automatic glass production: glass melt is poured out
© Fraunhofer ISC
Fully automatic glass production: glass melt is poured out

© Fraunhofer ISC

Automated specialized systems for modern materials development

Automated specialized equipment for glass and ceramic materials

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Automated system for the production of new specialty glasses

The Center of Device Development CeDeD designs and manufactures automated specialized equipment and systems for key tasks in materials research and development. Our custom-built systems support companies and research institutions in reliably producing complex functional materials and in evaluating new material compositions more quickly. The focus lies on precise raw material handling, clearly defined and reproducible process steps, and end-to-end data acquisition. This enables faster development of new materials, targeted optimization of existing formulations, and efficient scaling of production processes. Central application areas include automated glass development and the production of ceramic materials.

Automated materials development

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Production of new technical specialty glasses

Glass has played an important role in human life for more than two millennia, from classic everyday products to innovative high-tech applications in optical systems, bioactive implants, and energy materials. Despite the long history of this material, only a small fraction of all possible glass compositions has been discovered or thoroughly investigated. Developing or introducing new multifunctional glasses is often time-consuming and costly.
CeDeD has developed a robot-controlled system that accelerates and automates the research and production of technical specialty glasses. This allows new glass compositions to be tested more quickly and their properties to be reliably analyzed. The system is designed for both research institutions and industrial development processes and enables reproducible results under controlled conditions.
 

Material preparation and sample production

The system processes various glass raw materials precisely according to individual formulations. Automated mixing and melting steps ensure homogeneous samples whose composition can be specifically adjusted. During production, mechanical, thermal, and chemical properties are continuously recorded, enabling systematic evaluation of data such as elastic modulus, solubility, or glass transition temperature.
 

Safe process control

All process steps take place within enclosed systems that protect materials from contamination and operators from risk. Robotic arms are equipped with sensors that automatically stop movement upon contact. The system thus meets high safety standards for both laboratory and industrial environments.
 

Digital control and workflow integration

Through digital interfaces, all process data is captured, centrally analyzed, and integrated into a seamless workflow. This enables data-driven advancement of glass materials, higher process quality, and faster material testing. As a result, new glasses can be developed more quickly, existing compositions can be improved in a targeted way, and research results can be efficiently transferred into production readiness.

The glass screening system

Video: Youtube

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The robot-controlled process line is worldwide unique and covers four main process steps, which are handled by a robot and controlled by a main control station.


These four steps are:

  1.  Mixing and weighing of up to 14 glass components
  2.  Powder homogenization via robot mixing procedure
  3.  Heating and melting with 3 inline furnaces up to 1.700 °C / 3,092 °F
  4.  Casting and controlled cooling with a special designed 3 zones cooling furnace

The robot autonomously performs these process steps using different types of gripping tools and several automated routines. All data (e.g. weighing results) are recorded digitally and reported during the entire process. The high level of automation facilitates up to 20 glass samples per day (depending on complexity of the glass composition) to be produced. Based on all data, the process line will be optimized through a feedback loop, generated by a digital twin, which is connected to the digital workflow and localized on a central material data server.

 

Production of new ceramic materials

The system developed by CeDeD automates and optimizes the production of new ceramic substances and materials. It is specifically designed for materials development, ceramic production, and industrial high-tech manufacturing, enabling reproducible and precise production of complex ceramic materials. This makes it a reliable solution for both research laboratories and industrial applications.
 

Precise raw material handling and dosing

The system can process up to 100 different ceramic raw materials, including alumina and titania. Equipped with four large and six small material reservoirs, it ensures precise selection and secure storage of raw materials. A fully automated weighing system guarantees that all materials are dosed exactly according to customer-specific formulations.

The resulting powder mixture is then automatically combined with liquids, which can be individually selected from up to seven different options. The mixing takes place in a specialized mill, producing a homogeneous, high-quality ceramic slip that is subsequently processed in an innovative spray dryer. The final product consists of customized ceramic components, distinguished by properties such as high conductivity, versatility, and adaptability to a wide range of applications.
 

Occupational Safety and Process Protection

The system meets the highest safety standards for both research and industrial environments. The robot is equipped with touch sensors around its arm and gripper, which immediately stop the system as soon as human contact is detected. This eliminates the need for additional safety fences or sensor fields, allowing operators to work safely in close proximity to the system.

All powder and liquid dosing systems are fully enclosed and feature connections for dry air to protect materials from moisture and prevent explosive atmospheres. Additionally, the attrition mills are ATEX-certified, allowing safe handling of flammable liquids such as ethanol.

The combination of automated safety features, enclosed system design, and certified milling technology ensures a highly secure workflow, minimizes risks to operators, and safeguards the quality of the produced ceramic materials.

The ceramic screening system

Video: Youtube

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Highly Automated Production Process

The production workflow is fully automated:

  1. Selection of powder containers by the robot and precise dosing according to the recipe
  2. Transport of powders to the mill
  3. Selection and dosing of liquids
  4. Homogenization of powder and liquid in the mill
  5. Further processing in the innovative spray dryer
  6. Extraction of the ceramic slip via a valve that safely retains the milling balls


Technical Highlights

  • Processing of up to 100 ceramic raw materials
  • Fully automatic dosing of powders and liquids
  • Three specialized attrition mills with zirconia lining
  • High-precision robot control and industrial software for recipe management
  • Innovative spray dryer for high-quality ceramic slips
  • Tailored solutions for research, prototyping, and industrial production