Fraunhofer IST: Selective Surface Treatment Instead of Electroplating
A new EJP platform at Fraunhofer IST combines selective electrochemical surface treatment with robotics. This enables complex components to be locally structured, smoothed, repaired, or coated while conserving resources.
By expanding its research infrastructure, the Fraunhofer Institute for Thin Film and Surface Technology IST is establishing a new platform for local electrochemical surface processing. The combination of electroplating processes with technologies such as Electrochemical Jet Processing (EJP) and robotics enables the precise and resource-efficient processing of complex workpieces. Electroplating imparts specific functional properties to components, improves their durability and performance, and can help conserve resources by extending their service life. Against this backdrop, Fraunhofer IST is combining established electroplating processes with selective approaches to surface treatment.
EJP Enables Localized Processing and Coating
At the heart of the facility expansion is the new Electrochemical Jet Processing (EJP) platform, which combines various selective electrochemical processes for localized machining and functionalization of surfaces. These include Electrochemical Jet Machining (EJM) for non-contact, micrometer-precise material machining, as well as Electrochemical Jet Deposition (EJD) for the localized deposition of functional layers. Surfaces can thus be selectively structured, smoothed, repaired, or coated. Unlike traditional electroplating processes, the EJP platform uses a movable electrochemical jet that acts only where material is to be processed or layers are to be deposited. This makes it possible, in the future, to flexibly process even complex or large-scale components. Restrictions imposed by process baths as well as masking and demasking steps are eliminated. At the same time, the use of chemicals, energy, and raw materials—as well as the amount of waste—can be reduced.
Robotics for Complex Component Geometries
The platform is complemented by a robotics and automation infrastructure. High-precision industrial robots and autonomous mobile robots support machining as well as material and tool logistics. The processes can thus be adapted to different component geometries and integrated into automated production lines. Among other things, the system technology enables the material-friendly production of microstructures with high deposition rates, as well as the targeted filling and coating of micro-holes. In the future, the EJP platform is to be linked even more closely with robotics, sensor technology, and data-driven control methods. The goal is an adaptive manufacturing system that continuously optimizes processes and reduces resource consumption and scrap.
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