High Performance Manufacturing

We work on the development, provision and adaptation of production and manufacturing technologies as well as the necessary machine and control technology necessary for manufacturing of innovative products. It is IPK Project Office for Advanced Manufacturing at ITA`s goal to strengthen and improve the competitiveness of our partners in the long term with application-specific detail and system solutions. We develop new machines and machining strategies, optimize existing production facilities and implement futureoriented tool concepts. We support manufacturers in the development and introduction of new product-related services.




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Development of machines, tools & devices for manufacturing processes

πŸ“„ High performance machines
New machine-tool concepts and solutions for plant and process automation

πŸ“„ Industry 4.0
Flexible Transparent Manufacturing

πŸ“„ Flexmatik 4.1
Development of more accurate process kinematics

πŸ“„ Performance Assessment of Machine Tools Based on Structural Stiffness
Mapping the machine’ structural behavior and its influence on the geometrical accuracy of a machined part

πŸ“„ EFIP-EFORB – Devices for Aircraft Structures Assembly
Development of end-effectors to complement the necessary tasks for the automation of aircraft structural assembly

πŸ“„ EXOBOT – Mobile Robotic Force Amplification System
Development of a force amplification system to handle large pipes



Development and optimization of machining processes

πŸ“„ High Performance Production
Development, deployment and adaptation of production and manufacturing technologies

πŸ“„ Industrial robots as machine-tools
Flexibility, precision and automation with industrial robots

πŸ“„ Industry 4.0
Flexible Transparent Manufacturing

Performance and efficiency of industrial robot

πŸ“„ Evaluation of the cast iron Drilling process
Evaluation of the drilling process, regarding machinability of the cast iron, using minimum quantities of lubricant (MQL) and flood rating

πŸ“„ Analysis of the valve seat machining process
Evaluation of the influence of material and cutting parameters in the machinability of guide seats

πŸ“„ Optimization of the screw connection for closing a planetary gear unit
Analyze the interaction between surfaces and their connection to the state of finishing in order to optimize the screw connection used to close a planetary gear unit

πŸ“„ Machinability Evaluation of Three Similar Medium-Carbon Alloys
Evaluation of the differences between both alloys in what concern the machinability, specially the chips characteristics

πŸ“„ Machinability of the new materials for automotive valve guides
Investigation of the machinability of new materials for automotive valve guides with different surface treatment conditions

πŸ“„ Comparative study of Aeronautical Component Manufacturing using 3 and 5 axis machines
Analysis of the differences between 3-axis and 5-axis milling in aeronautical components

πŸ“„ Machinability evaluation – Drilling Process
Analysis of three Compacted Graphite Iron (CGI) types on machining operation to manufacture precision holes

Development and optimization of forming processes

πŸ“„ Tool and mould making
Development of special technological solutions & production equipment and set-up of process chains

πŸ“„ Industrie 4.0Β  LINK
Flexible Transparent Manufacturing

πŸ“„ Proposal for the optimization of mold and matrix machining processes
Programming procedures and definition of processes parameters.

πŸ“„ Integrity of Advanced High-Strength
Research to investigate the influence of the welding parameters on the integrity of AHSS weld spots and to understand how significant is the effect of a processing chain on the integrity when compared to the β€œas-welded” condition

πŸ“„ TDO 4.0 – New Die Tryout Concept
Development of online monitoring tools to diminish manual interventions during the tryout stage of sheet metal forming dies

πŸ“„ Surface defects assessment
Analysis of the feasibility to develop a defect identification system in sheet metal stamped

πŸ“„ Research and development of new materials and manufacturing processes for stamping tools that minimize surface defects
Evaluation of the results using an exerto of polymeric material in tool and die stamping

Development and optimization of welding and coating processes

πŸ“„ Laser beam and hybrid welding
Process development, parameters determination and technical & economic assessment

πŸ“„ Optimization of the welding sequence on complex assemblies
Flexible Transparent Manufacturing

πŸ“„ Industrie 4.0Β  LINK
Flexible Transparent Manufacturing

πŸ“„ AGE Project – Automation of the Construction and Installation of Large Scale Industrial Reservoirs
Development of a high innovative process through automatic align with industrial robots using a programming called cooperative movement

πŸ“„ Spot Welding Process
Development of AI models with data responses from resistance welding process

Development and optimization of hybrid manufacturing processes

πŸ“„ Post-processing of TI6AL4V Preforms Manufactured by Wire Arc Additive Manufacturing (WAAM)
Evaluation of the relevant aspectsfor the integration between additive and subtractive manufacturing process of Ti6Al4V walls produced by Wire Arc Additive Manufacturing

πŸ“„ New process combination for efficient metallic coatings
Combination of laser and plasma powder deposition welding in one process zone

Development of process chains for repairing of high added-value components

πŸ“„ FERA Feasibility Study – Tools and Gears Repaired Additively
This feasibility study aimed to explore the challenges of additive manufacturing application for gear teeth repair and the evolution to a robust design

πŸ“„ System technology for laser beam repair welding
Continuous quality control during laser cladding

Surface- engineered solutions for the manufacture of gears

πŸ“„ Application of the Hall Effect for the Assessment of Thermal Damage
Investigation of the proposal for a method of surface magnetic scanning through the Hall effect, without the use of component magnetization sign

πŸ“„ Development of the Powder Metallurgy chain for High Performance Automotive Gears
Application of the “integrated product development” method to the design of the powertrain components manufacturing chain

Assessment of durability and NVH in rotary systems

πŸ“„ Investigation of the effect of microalloy elements in special steels on the durability of gears
Analyze the interaction between surfaces and their connection to the state of finishing in order to optimize the screw connection used to close a planetary gear unit

πŸ“„ Assessment of the Manufacturing Chain on the Fatigue Behavior of PM Gears
Identification of the fatigue behavior of gears subjected to an alternative powder metallurgy manufacturing chain, recording them by using an S-n curve

How to cooperate with us

A step-by-step guide
  • Company approaches the Fraunhofer IPK Project Office for Advanced Manufacturing at ITA with an inquiry
  • Definition of project scheme
  • The international team of experts, together with the company, discuss and defines and the project scope, demands and requirements
  • Our team proposes the best contract model for hiring the Fraunhofer IPK Project Office at ITA, which depends on the division of work and financing source
  • A proposal is developed by our team
  • The contract between the parties is prepared and the company places the order (non-disclosure agreements can also be prepared in parallel)
  • We carry out the project
  • Presentation of results upon project completion


Prof. Dr. Ronnie Rego

Head of Operations Fraunhofer IPK Project Office for Advanced Manufacturing at ITA

Phone: +55 12 3947-6948

Dr.-Ing. David Carlos Domingos

Head of Operations Fraunhofer IPK Project Office for Advanced Manufacturing at ITA

Phone: +49 30 39006-413