Fraunhofer IST at Automatica 2025: Innovative thin-film sensor technology
At Automatica 2025, the Fraunhofer Institute for Surface Engineering and Thin Films IST will be showcasing an innovative sensor system that records process data such as temperature and pressure in real time directly in the mold.
In the context of Industry 4.0, the precise recording and monitoring of relevant parameters such as temperature and pressure curves in plastic injection molding is essential. At Automatica 2025, the Fraunhofer IST will be presenting multifunctional thin-film sensors that are deposited directly on the mold surface. These sensors enable spatially resolved real-time measurement of the temperature in the main stress zones of the injection molding process. One example is the thin-film sensor system developed at the Fraunhofer IST, which was applied to an exchangeable mold insert. With 13 measuring points, it offers a comprehensive analysis of the flow front. The thermoresistive sensors are arranged in such a way that they precisely map the component geometry.
Fraunhofer IST trade fair stand at the Automatica 2025
A specially adapted electronic unit reads out the collected data in real time and processes it directly. With the help of intelligent automation using machine learning algorithms on edge devices, faults and weak points can be detected immediately. The component quality is reliably determined and output as a color signal even before the mold is reopened after the injection process. This enables corrections and adjustments to be implemented quickly. Due to the high wear resistance of the thin-film system, it is also possible to monitor processes with a high proportion of glass fiber and recyclate. This is a significant contribution to the use of sustainable materials in production as part of the circular economy. Visitors to Automatica 2025 can find out how real-time data acquisition with sensory mold inserts works during the injection molding process at the Fraunhofer IST stand at the Fraunhofer joint stand in the Fraunhofer autoMOBILproduktion alliance area (Hall A4, Stand 319).