Engineering of Materials and their Manufacturing Processes

We specialize in transforming fundamental material science into industrial reality. Our core strength lies in bridging the gap between laboratory-scale innovation and high-volume manufacturing by seamlessly merging advanced material characterization with our deep expertise in thermal treatments and high-energy electromagnetic processes.

Key capabilities

• Rigorous Design of Experiments (DoE) for novel composite formulations
• Microstructural and phase mapping via XRD, FTIR, SEM, and EDX
• Chemical resistance, corrosion, and phase-diffusion stress testing
• Thermal and mechanical profiling (TGA, DSC, tensile, compression, hardness)
• Custom laboratory-scale miniplants for continuous pilot validation
• Full industrial upscaling, HAZOP analysis, and PLC process automation

Technical Focus

Working in close cooperation with the University of Bayreuth, we utilize rigorous Design of Experiments (DoE) to engineer and validate novel composite materials, breaking down complex material profiles into actionable data:

• Structural Mapping: We evaluate phase morphology, structural integration, and physical bonding using X-Ray Diffraction (XRD), Fourier-Transform Infrared Spectroscopy (FTIR), Scanning Electron Microscopy (SEM), and Energy Dispersive X-Ray Spectroscopy (EDX).
• Environmental Stress Testing: We validate how composites behave under demanding conditions, testing for phase diffusion, corrosion effects, and long-term chemical resistance in extreme acidic or basic environments.
• Thermal Profiling: To guarantee stability under intense processing, we map precise thermal responses using Thermogravimetric Analysis (TGA) and Differential Scanning Calorimetry (DSC).
• Mechanical Validation: We ensure industrial readiness through rigorous physical evaluations, including tensile strength, compression testing, and durometer hardness profiles.

Achievements

• Process Engineering: We develop innovative, customized production processes tailored precisely to customer requirements. This phase encompasses the creation of comprehensive process flowsheets, rigorous HAZOP safety analyses, and detailed financial and risk evaluations. We engineer the entire ecosystem—designing complex peripheral systems, managing critical waste streams, and coordinating specialized external partners to set a robust foundation for plant automation.
• Pilot Plant Validation: Before committing to full-scale investment, our team designs, builds, and operates custom laboratory-scale „mini-plants“. This crucial transitional phase allows us to rigorously test continuous process stability, refine thermodynamic parameters, and gather real-world operational data, practically proving that the precise material quality achieved in the lab remains consistent within a dynamic manufacturing environment.
• Industrial Upscaling & Automation: The final step is optimizing the complete production chain for high-volume manufacturing. We work in close cooperation with our industrial partners to seamlessly integrate advanced automation architectures into the final facility—incorporating comprehensive sensor networks, PLC integration, and custom control loops to guarantee continuous material homogeneity, structural durability, maximum energy efficiency, and a significant reduction in overall process waste at an industrial scale.