Scaling Effects in Dimensional Metrology and Autonomous Positioning

Research Focus Area 5 examines scaling effects in dimensional metrology alongside novel manufacturing technologies. A key focus is how measurement configurations impact resulting measurement uncertainty – particularly with flexibly adaptable measurement volumes. These relationships are modelled and analysed using proprietary models. Additionally, an automated manufacturing sequence is being developed to apply and calibrate highly precise, component-integrated sensors scalably and independently of component size using the proposed large-scale equipment. Reliable integration requires high surface quality and secure encapsulation of the sensor technology. Accordingly, suitable surface pre-treatments and encapsulation methods are researched to enhance electromagnetic compatibility and provide protection against environmental influences. 

The resulting sensors enable precise functional assessment of components and provide essential data for flow simulations, deformation analyses, and usage and service life monitoring of large components (Research Focus Area 6).

This foundation allows component stresses to be captured, compared against stress limits, and efficiency gains to be achieved – particularly in validating innovative additive manufacturing and repair processes.