Partners

CMO-SYS GmbH develops systems for measuring and inspecting components and processes across industries, using a wide range of technologies and methods.

Its machine vision expertise ranges from basic vision systems to 3D inspection and measurement, X-ray technology, spectral analysis and interferometry. Tactile methods include conventional probing and force–displacement or torque–angle measurement, also combined with real-time robotic actuation.

Magnetic field, volume, density and sound pressure measurements, together with leak and burst-pressure testing, complete the range of physical measurement methods.

To deliver turnkey systems, the company combines inspection technology with component handling, bin and belt picking, and production-line integration.

Custom database systems and analysis tools store and evaluate production and inspection data, with interfaces to a wide range of higher-level systems.

IDECO supplies testing and treatment technologies for molten metals in aluminium production and casting. Its team of IT, measurement, control and foundry specialists draws on 35 years of practical experience to develop, manufacture and supply customised systems for:

• Cleaning and treating aluminium melts using impellers

• Thermal analysis of solidification characteristics, grain refinement, primary silicon refinement and modification

• Pore potential assessment and hydrogen control using VACTEST, density index measurement and Hycal in-situ hydrogen measurement

• Temperature measurement for melting and heat-treatment processes

• Connectivity, digitalisation and analysis: tailored documentation and evaluation of testing and treatment data, integrated into customer networks and adapted to project requirements

Completed Euronorm and AiF research projects addressed thermal analysis (EP170708) and simulation (ZF 4624501LL8). Current projects focus on feeding analysis and factors influencing porosity. Customer projects over the preceding two to three years concentrated on Foundry 4.0, with customised connectivity, digitalisation and analysis solutions.

Wollin GmbH is a family-owned engineering company led in its second generation by Björn Wollin. It has developed and manufactured die casting automation solutions in Lorch, Baden-Württemberg, for more than 50 years and employs around 75 people at the site.

Sustainability informs both product development and site operations. The company generates around 70% of its annual electricity needs on available roof and site areas. Its CNC machining hall, built in 2007, uses waste heat recovery supported by a ground heat collector and requires no additional heating energy.

Release-agent application is its core die casting activity. Wollin supplies linear die spraying systems, equipment for common industrial robots, and release-agent mixing and supply systems worldwide. Innovations such as patented Eco+/EcoSpray nozzles improve casting quality and productivity while reducing resource use.

Wollin aims to lead technology in this field and regularly participates in publicly funded research. Projects include work with GTK (InMoDie, TTP LB), TU Braunschweig's ifs (RELEASE/ProLok, AiF), IFAM Bremen (VerA, AiF) and Aalen University (gas injection in die casting, ZIM).

Founded in 1997 as Erhardt + Abt Automatisierungstechnik GmbH, HEITEC PTS initially focused on manufacturing automation. Production X-ray inspection joined its portfolio in 2012, first with 2D radiography and, from 2018, 3D computed tomography. It is a subsidiary of HEITEC AG, which combines expertise in automation, digitalisation and electronics.

HEITEC PTS systems are widely used in aluminium foundries, particularly for automotive castings. Since 2012, HeiDetect Wheel Robot systems have inspected 13–26 inch alloy wheels automatically within production cycle times, using Fraunhofer EZRT's ISAR software for defect detection. Inspection results and images are stored in line with customers' traceability systems. Around 80 installations are in operation. The optional HeiLaser Wheel unit engraves a data matrix code after inspection, linking each wheel to its results.

Other 2D systems include HeiDetect Flex Robot, whose six-axis robot and interchangeable grippers inspect large aluminium components of varied geometry. A scalable radiation enclosure with modular inspection components and robots was developed for especially large automotive castings. Alongside inspection quality, full automation and production-line integration require reliable component identification and permanent access to inspection results.

For 3D inspection, HeiDetect FX InlineCT scans thick-walled aluminium castings at 450 kV, while HeiDetect Live View handles less massive parts at up to 225 kV. Both acquire and automatically assess CT scans within typical foundry cycle times. Production integration includes component handling and data matrix identification, currently using customer-specific proprietary solutions.

For two decades, BREOS has provided digitalisation expertise and turnkey solutions for efficient, transparent processes and applications. It acts as a think tank for data and AI.

BREOS works with leading German and European companies and has experience in manufacturing, logistics, retail, e-commerce, pharmaceuticals, automotive, insurance and services.

BREOS combines scientific foundations, interdisciplinary expertise and practical experience to create digital solutions that simplify work. Tailored AI-based end-to-end solutions address complex challenges through a single point of contact. Open communication supports transparency, trust and successful technology integration. Human creativity and strategic thinking are combined with AI to develop user-friendly solutions. Sustainable software development prioritises reliability, long-term use and adaptability, with innovation and collaboration between people and technology at its core.

insightfabrix solutions GmbH develops and operates Industry 4.0 solutions for die casting foundries. Its smartfoundry.solutions software, hardware and cloud components can be combined into customised data acquisition, processing and visualisation systems. The range includes sensors, managed edge devices, status boards, input and visualisation terminals, assistance systems, and a web-based application platform with associated apps.

bridgefield GmbH develops digital solutions to complex enterprise challenges. It aims to become a leading German specialist in shopfloor digitalisation. Its core expertise is system and data integration in brownfield environments, where limited sensors, heterogeneous processes and substantial manual work create a particular need for intelligent assistance.

Through ReGAIN, bridgefield expands its expertise in inter-company communication. The Catena-X network extends shopfloor data collection and exchange across the production chain. Although developed for automotive manufacturing, the network can be applied to other production sectors, broadening bridgefield's portfolio for future customers and projects.

MAGMA develops and supplies casting process simulation and virtual optimisation software worldwide. Its portfolio includes MAGMASOFT® autonomous engineering and engineering services for casting design and manufacturing optimisation.

MAGMAacademy provides comprehensive implementation and continuing education services in casting simulation for more than 2,000 customers worldwide.

Founded in 1988 and headquartered in Aachen, Germany, MAGMA Gießereitechnologie GmbH operates through offices and subsidiaries in the USA, Singapore, Brazil, Korea, Turkey, China, India and the Czech Republic. A further 30 qualified partners represent MAGMA worldwide.

PINTER GUSS GmbH is a medium-sized foundry with more than a century of experience. The group combines modern equipment and innovation with collaborative research. It designs, optimises and manufactures aluminium and copper alloy components using sand, permanent mould and low-pressure casting for machinery, medical, drive, pump and energy technology, specialist vehicles, agricultural machinery and commercial vehicles. Digital production, data acquisition and analysis, and system connectivity are key priorities.

PINTER GUSS has pursued digitalisation for several years, establishing a database-based manufacturing execution system across all production workstations. Custom software creates an industrially robust, deeply connected solution tailored to operational needs.

An article by IHK Niederbayern describes this work (https://www.ihk.de/niederbayern/presse/online-magazin/titelthema-pinter-guss-5592580). The existing IT infrastructure and production data/MES environment provide a strong foundation for practical research results.

Student research with the Technical University of Munich has explored component traceability using machine learning to recognise stochastic surface structures on permanent mould castings across multiple production stages. ReGAIN builds on and extends these preliminary results for practical use.

LGL Leichtmetallgießerei Bad Langensalza GmbH specialises in aluminium castings. As a full-service foundry, it offers consulting, development, machining, assembly and logistics. Continuous investment and participation in innovative research support high quality standards. Customers include the electrical, automotive, medical technology and wind energy sectors.

G. A. Röders GmbH & Co. KG is a family company with over 200 years of history, led in its sixth generation by Andreas and Gerd Röders. Around 480 employees produce aluminium and zinc die castings and plastic injection mouldings at three sites in Germany and the Czech Republic. The company has its own toolmaking and CNC machining facilities.

Röders has worked on sustainability for many years, introducing ISO 50001 energy management and, in 2022, ISO 14001 environmental management. Research projects address energy savings, scrap reduction, alternative materials and sustainable processes and products. In 2022, Dräger awarded Röders its supplier sustainability prize.

BDG represents the diverse interests of the largely medium-sized German foundry sector. With 600 companies and approximately 70,000 employees, the industry is a major supplier to vehicle, machinery and plant manufacturing. Foundries work closely with suppliers and customers to turn knowledge and innovation into practical solutions. BDG advises its members, supports knowledge transfer through committees, and represents the sector regionally, nationally and at European level.

With over 3,600 members, VDMA is a major network and representative body for mechanical and plant engineering in Germany and Europe. It represents the industry's economic, technical and scientific interests. Its experience in OPC UA Companion Specifications, international partnerships and extensive network help translate ReGAIN information models and reference architecture into practical, widely adopted standards.

VDMA's II4IP project (funding reference 13I40V003A) developed the harmonised OPC UA for Machinery foundation. It covers identification, job management, machine status, process values, operating counters and consistent energy data. The resulting standards include OPC UA 40001, 40001-2, 40001-3, 40001-101 and 34100.

VDMA also coordinates numerous OPC UA working groups, which have published more than 60 standards.

IWF is jointly led by Prof. Dr.-Ing. Klaus Dröder and Prof. Dr.-Ing. Christoph Herrmann, who hold the chairs of Manufacturing Technologies and Process Automation, and Sustainable Manufacturing and Life Cycle Engineering.

The Sustainable Manufacturing and Life Cycle Engineering chair develops concepts, methods and tools for life-cycle-oriented planning, design, control, analysis and assessment of products, process chains and production systems. Research focuses on energy and resource efficiency and quality and cost optimisation through digital technologies. Sustainable cyber-physical production systems connect real production with digital models based on simulation and data analysis.

The ifs has six research areas: adhesive bonding and mechanical joining; welding and beam technology; strength and component behaviour; material composites and interfaces; fibre composites and electromobility; and light metal die casting. The die casting group conducts fundamental and applied research to advance products and processes. Core topics include sensors and data acquisition, process optimisation using AI and simulation, analysis and reduction of the CO2 footprint, and the joining suitability of die castings. It operates a dedicated die casting cell at the Soltau Light Metal Centre. Relevant publicly funded work includes Zukunftslabor Produktion (Lower Saxony MWK, 2019–2024, ZN3489) and process optimisation to reduce the CO2 footprint of secondary aluminium die casting (OptiProGRessAl, BMWK, 2022–2024, 03LB3040G), demand-oriented release-agent application to reduce die sticking (RELEASE, BMWK, 2021–2024, IGF 21.609N), and numerical calculation and validation of ejector forces and distortion (NBVAB, BMWi, 2017–2019, IGF 19.258N). ReGAIN extends these approaches for die casting.

For over 20 years, Fraunhofer IIS's EZRT has developed industrial X-ray solutions, including application-specific equipment, hardware, control, radiation protection and software. Its PMO department focuses on image processing, CT reconstruction and automated image evaluation using conventional algorithms and AI.

The main application is highly automated, process-integrated 2D and 3D X-ray inspection. A core product is ISAR, used for automated inspection of castings and other industrial applications.

Fraunhofer EZRT develops and owns ISAR, an advanced system for automated radioscopic inspection. (https://www.iis.fraunhofer.de/de/ff/zfp/produkte/isar.html)

Fraunhofer IFF in Magdeburg researches production technology, focusing on factory planning, operations and industrial automation. Its digitalisation, machine learning and AI expertise enables connected, energy-efficient and resilient production. Building on Catena-X, it works with ReGAIN partners on future-ready, energy-optimised foundry production and logistics and their integration into connected value creation systems for a sustainable, competitive industry.

For more than 30 years, Fraunhofer IFF and its industrial and academic partners have developed solutions combining environmental responsibility and economic success. The institute supports public-sector challenges and accompanies companies of all sizes and sectors on their path towards tomorrow's production.

Kempten University contributes transferable expertise from its own and external research. Scientific publications and public exchange make project findings accessible and advance digitalisation and production automation. Interdisciplinary expertise and industrial collaboration produce practical solutions benefiting both science and industry. IPI and 3Dvisionlab work together on research in this field.

3Dvisionlab has extensive sensors for optical 2D and 3D environment capture and expertise in image processing, covering the full chain from acquisition to actionable recommendations. Three professorships cover optical design, conventional image processing and AI-based image processing. Previous projects include a prototype for marking sand castings and a customised vision system predicting tool failure in stamping and bending production. Joint research with IPI focuses on data generation and analysis, AI, digital twins and sensors.

Kempten University contributes transferable expertise from its own and external research. Scientific publications and public exchange make project findings accessible and advance digitalisation and production automation. Interdisciplinary expertise and industrial collaboration produce practical solutions benefiting both science and industry. IPI and 3Dvisionlab work together on research in this field.

IPI in Sonthofen conducts applied research at the interface of science and industry. Foundry research covers resource and energy management and data-driven process optimisation. HyProForm developed a sand preparation control system using new measurement techniques and hybrid control algorithms for complex thin-walled castings. OPTIRODIG investigated digital links between recycling and foundries for automated raw material supply and circular resource use. REFFpro developed an assistance system predicting energy and resource consumption from digitalised operations. Other projects address production machine learning, the industrial metaverse, digital twins and additive manufacturing. IPI supports SMEs and runs the Alpine region's Industry 4.0 network. Further information is available at https://www.hs-kempten.de/forschung/forschungsinstitute/ipi-institut-fuer-produktion-und-informatik/forschung .

Bühler AG offers a broad portfolio of die casting equipment and services, from individual machines to integrated cells tailored to specific applications. More than 100 service locations, application centres and machine refurbishment facilities in Europe, Asia and North America provide global support and customer proximity.

AWEBA Group is one of Europe's largest and most modern toolmaking businesses. Its worldwide services cover product development, tools and fixtures, maintenance, repair and spare parts throughout the product life cycle.

The ae group supplies high-quality die castings, particularly for automotive applications. Its expertise combines precision, quality and innovation with application-oriented consulting and component development. Modern technologies, advanced production methods and tailored material solutions address individual customer requirements.

Julius Schüle Druckguss GmbH is an international die casting and machining company with extensive foundry experience. Modern technologies produce high-quality parts for automotive, electronics, household appliances, pneumatics and other industries. Close customer collaboration delivers tailored solutions. Multiple European sites support efficient logistics, responsiveness and flexibility across its production network.

FONDIUM Group GmbH, an automotive iron casting supplier, participates as an associated partner. It transfers the developed AI models to iron casting, supplies process data and conducts usability tests. Practical validation and optimisation support acceptance and adoption of the project results across the foundry industry.

Matho Energie Management GmbH is a family-owned company with many years of electrical industry expertise. Its main services include:

• Turnkey industrial energy data management systems and measurement equipment, including services

  Uninterruptible power supplies for IT, medical, critical infrastructure and industrial applications

• Products and services for residual current measurement and peak load management
• Products and services for power quality and electromagnetic compatibility
• Sizing and supply of reactive power compensation systems, active and passive filters, reactors and related equipment

The company provides complete solutions from a single source and supports all process participants.