Future of production: Innovative tool concepts for more flexibility!

Future of production: Innovative tool concepts for more flexibility!

Industrial manufacturing is undergoing rapid change, caused by increasing customer individualization and shrinking batch sizes. These changes require innovative solutions to produce components more flexibly, efficiently and in a more resource-saving manner. At the University of Siegen New tool concepts are therefore being developed to meet these challenges. The research project, led by Prof. Dr.-Ing. Bernd Engel and Prof. Dr. Ulf Lorenz, is funded by the German Research Foundation (DFG) with around 568,000 euros until 2027.

The focus of the project “Kinematic tool-bound profile bending using transformer tools” is on improving forming techniques, which are often perceived as rigid and not very flexible in industrial production. Traditionally, these rigid forming tools usually require a separate tool for each new geometry, which is time-consuming and cost-intensive. The research team is therefore developing alternative tool concepts with a segmented, adjustable design in order to realize different component geometries with one tool set.

New approaches for sustainable production

The increasing demand for small series and the need for sustainable business are clear indicators that forming technology is facing major challenges. Since 2023, the DFG has been funding innovative approaches that not only increase efficiency but also conserve resources. Advanced algorithmic and mathematical structural optimization approaches are used to research new designs. The aim is to make production more flexible and efficient, which is closely related to the global resource transition.

In the production of the future, companies will be required to design their processes sustainably. Climate change and resource scarcity are key factors driving growing demand for environmentally friendly products and efficient manufacturing processes. Digital technologies are driving change in production and enabling more flexible and efficient processes. The Production of the future is also characterized by the use of recycling and reuse of materials in order to minimize resource consumption.

The role of new technologies

Innovative technologies are crucial for minimizing waste and reducing energy consumption. Digital technologies, such as sensors, IoT devices and data analysis, optimize production processes in real time and are the cornerstone of the “Smart Production” concept. In addition, metal powder-based 3D printing opens up new perspectives for the functionalization of tools. Not only transformer tools are researched, but also wooden tools, 24h tools and secondary tools.

The long-term vision of the research team at the University of Siegen includes the development of highly flexible “intelligent tools” equipped with sensors and actuators. These tools should be able to automatically adapt to changing requirements and thus lead to highly flexible manufacturing processes. Close collaboration between industry, research and politics is necessary to actively shape this change and fully exploit the potential of digitalization.