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In the midst of a paradigm shift. How can low-cost cobots be adapted for precision measurement technologies?

In the midst of a paradigm shift. How can low-cost cobots be adapted for precision measurement technologies?

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At the end of last week, the one-year 3D-FMM research project, which focuses on the development of a modular and adaptable manufacturing measurement platform, was concluded with a ceremony held at the Suhl-based company PREMETEC. This research project serves as an example of how productive cooperation between regional companies and universities of applied sciences can function in the spirit of mutual knowledge transfer.

The project addressed a specific question that simultaneously opens up a broad spectrum of potential applications: Is it possible to build an automated measurement station that is cost-effective, versatile, and highly precise? Within this framework, the project partners were able to collaborate productively, each bringing their own perspectives: On the one hand, Schmalkalden University of Applied Sciences, specifically a team from Professor Frank Schrödel’s Chair of “Drive, Automation, and Robotic”s led by Nikhil Meduri and Niranjan Kannali Ramesha; and on the other hand, the Suhl-based company PREMETEC, a “hidden champion” in southern Thuringia with expertise in measurement technology and testing systems. A particular challenge was the cost-efficient design of the project, which was also reflected in the use of low-cost robots.

The use of collaborative robots is gaining momentum in the industry: Unlike full automation, the focus here is on human-machine collaboration, which presents challenges for interaction, communication, and safety in the interaction between robots and humans. Cobots can assist with repetitive tasks such as assembly, pick-and-place, or quality control and optimize industrial workflows. In addition, they are easy to program and offer a high degree of workload reduction and occupational safety. Collaborative solutions are suitable for many industrial applications, and the range of different cobot models is expanding more and more. In addition to high-priced variants, there are also cost-effective models that generally perform simple tasks, though compromises must be made in certain operational qualities (such as speed).

As the automation of industrial production processes continues to advance, the question arises as to whether low-cost cobots can be used for specific tasks. Or, to put it another way: How can these cost-effective collaborative robots be technologically enhanced to perform high-precision measurement operations? Before we address this question and its solution, a few words are needed about PREMETEC and the challenges of high-precision measurement technologies.

Measurement Technology: The Balance Between Precision and Flexibility

Manufacturing companies require specific and high-precision systems for measuring their tools, components, and products. To ensure production runs as smoothly as possible, a control system is necessary that integrates seamlessly into production processes. For more than 30  years, the Suhl-based company PREMETEC has been dedicated to this challenge, providing the industry with high-quality solutions for measurement, testing, and automation. As a full-service provider of custom-fit measuring fixtures and automated testing systems, among other products, the company—which currently employs 27 people—develops and manufactures solutions optimized for each individual case. The quantity of products is usually just one, which underscores the high level of specialization and precision of the products.

In addition to the automotive industry and its suppliers, companies from sectors such as medical technology, security technology, and consumer goods production are increasingly becoming customers for these measurement technologies. PREMETEC’s portfolio includes not only compact and integrated solutions but also specialized measuring stations, measuring cells, and test benches. Beyond the actual measurement itself, a key challenge for measurement technologies is to integrate seamlessly into production processes. A production interval of one minute requires that the inspection also take less than a minute. Depending on the application and the complexity of the measurement, this can be more or less difficult.

The industry itself faces challenges, which also have consequences for companies like PREMETEC. Declining production volumes are a result of increasingly dynamic production cycles, which subject highly specialized measurement technologies to greater pressure to be profitable—a trend to which the industry must respond. One solution could be to design measurement technology to be flexible within certain limits, thereby making it usable for multiple products. Take, for example, a die-cast component of a tailgate, which has a complex geometry and must be manufactured with high precision to stay within the tolerance limits. The pressing question, therefore, is whether there is a way to avoid having to replace the entire measurement system when there are minor design variations.

One of the key challenges here is to ensure high quality, precision, and process integration while simultaneously allowing for flexibility in variable applications. One solution could involve the integration of cobots, which could be used within a modular measurement system for various measurement tasks. Affordable models, in particular, would enable small and medium-sized enterprises—which are characteristic of Thuringia—to utilize these solutions. The focus of the research project and the context of its application are now clear to us. However, the university’s work packages—that is, the specific areas of focus through which it contributed to the project—remain to be determined.

Cobots: Between Cooperation and Correction

First, it should be noted that the university addressed the topics of measuring the cobot’s precision and the possibilities for correction. Together with Nikhil Meduri and Niranjan Kannali Ramesha, a team from Professor Frank Schrödel’s “Chair of Drive, Automation, and Robotics” worked within and alongside PREMETEC over the course of the project to develop a solution for this task. The university’s project could be divided into three work packages, with the last two packages being interconnected. When measuring the robot’s precision, it is important to bear in mind that this is a low-cost cobot, not a specialized variant designed for such tasks. A consequence of this fundamental condition is that detailed statistics on the robot’s behavior and precision, particularly during continuous operation, have been lacking until now. The university has taken on this task.

The first work package focused on the conceptual design of the project and its organizational coordination. Precisely because the one-year timeline was quite short for such ambitious tasks, clarifying the basic structure was a key aspect. A distinction had to be made between the sensor area—including the measuring head and probe—and the actuator area, i.e., the robot. In particular, communication between the components had to be examined, and a focus had to be placed on the inaccuracy of the robot’s positioning. In short, the question was whether there were errors in positioning and whether these fell within a tolerable range.

In addition to the development of a control platform, the second work package focused on testing—that is, translating the system into reality. One problem that arose was the increasing inaccuracy of the robot arm as movement complexity increased: the more joints of the arm were activated during a rotational or gripping movement, the less precise the processes became. On the other hand, ensuring repeatability during continuous operation was a focus of the investigation. Among other things, the robotic arm was positioned 600 times at the same location, resulting in increasingly higher inaccuracy over the course of the process. Through this repeat positioning test and the analysis of the data, the Schmalkalden team was able to gain a far more comprehensive understanding of the robotic arm’s real-world behavior than had previously been available from the manufacturer.

This data is needed to assess the arm’s suitability for measurements. At the same time, it is important to keep in mind that repeated self-positioning is not part of these robots’ standard repertoire; rather, their focus is on the repetition of motion sequences. Nevertheless, knowledge of the error rate is crucial for assessing the suitability of the robots and the potential use of low-cost cobots. After analyzing the behavior, correcting the errors was the next step. One problem that emerged was the robot arm’s post-factual stubbornness, which, contrary to objective reality, assumed it was in the correct position. The question now was how to correct the robot’s behavior.

The solution involved the use of a proprietary 6-step algorithm: Using this adaptive software solution, the deviation could be compensated for without the need for complex mechanical interventions. This solution, utilizing a correction matrix, met the high precision requirements inherent in measurement technology applications, as well as the need for functional adaptability—that is, lasting flexibility in the application of measurement technology. This is further supported by the fact that the components required for correction remain external and are not fixed or implemented within the system itself. Thus, this machine learning solution remains autonomous and adaptive, which offers many possibilities for its further use.

Transfer and municipal, federal, and supranational cooperation

The paradigm shift noted in the headline consists in the fact that cobots are no longer merely auxiliary tools for measurement, but are themselves used for active measurement. A prerequisite for this is the precision made possible by the 3D-FMM project. Because precise handling tasks are becoming increasingly relevant in industry, this project also holds immense potential for further applications. In terms of technology transfer, potential can be harnessed both by universities and by companies such as PREMETEC and the manufacturers of the cobots.

The relevance and expected impact of the project for the Thuringian economic region were also evident in the funding provided by the “European Regional Development Fund” and the Thuringian Development Bank (TAB). In addition to Holger Haun from the TAB, Dr. Sebastian Stark was also on the guest list for the closing event; the latter heads the Technology Promotion Division at the Thuringian Ministry of Economics, Agriculture & Rural Affairs. Ariane Winkler and Sebastian Poppner also represented the municipal economic development agency of the South Thuringia Regional Center. The experiences gained in the transfer relationship, as well as the hurdles and challenges the project partners have overcome, can be shared through this network and pave the way for further research collaborations.

In the spirit of mutual benefit, the cooperation project offered advantages for all participants: For the company, it provides a technology that is nearly ready for the market and meaningfully expands its existing portfolio. For the university, it provided an opportunity for applied research that, in addition to insights and concrete data, also led to several publications. And last but not least, the project demonstrated a successful model for how international students can contribute productively to small and medium-sized enterprises. In this way, many opportunities were ultimately realized.

From Foe to Friend: How Communications Technology Can Make Use of Noise.

From Foe to Friend: How Communications Technology Can Make Use of Noise.

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The digitalization of society is not limited to smartphones; rather, it is driving comprehensive transformation across a wide range of sectors through trends such as the automation of mobility, smart energy management, and Industry 4.0. Even though we are accustomed to thinking in terms of “higher, further, and faster” in the digital realm—as exemplified by the demands on data volumes and transmission rates—there are also areas of application that are guided by opposing imperatives.

On the one hand, the idea of sustainability is becoming increasingly widespread, as evidenced, among other things, by the understanding of energy as a valuable, finite resource; on the other hand, the thoughtless waste of energy is certainly still an issue that manifests itself in various areas, such as the use of generative artificial intelligence. Beyond the broader societal context, however, there are also many other reasons to use resources such as energy or data consciously and efficiently.

Technologies that are, for example, geared toward principles of energy efficiency are already useful today: In addition to cash payments, credit cards, smartphones, and smartwatches are now widely used as payment options in everyday life. Even though this method of payment appears quite simple on the surface, it is based on complex technologies that simultaneously ensure the necessary security. Energy efficiency is an important aspect here, enabling secure communication over short distances.

What is communications engineering?

Electrical engineering, more specifically the field of communications engineering, deals with the question of how information is transmitted. In short, this involves the acquisition, conversion, transmission, switching, storage, and output of signals carrying information. The focus is on transmitting information as accurately as possible, with challenges arising not only at the signal input and output but also along the transmission path and in dealing with interference. In other words, this can be understood as the field of information and communication technology in the context of the technical infrastructure of a digital society.

The scope of this engineering discipline has expanded significantly in the course of the transition from analog to digital technology. At the same time, the emergence of modern information societies presents genuine challenges that require various technological solutions. On the one hand, this involves building a high-performance network infrastructure, as required by many sectors, such as autonomous logistics. The vast amounts of data and the need for real-time availability (as well as processing) demand optimal use of transmission technologies, channel capacities, and bandwidths to enable communication. On the other hand, there are application areas such as the aforementioned payments via debit cards and key cards (e.g., in car-sharing), where the focus is on authentication and security, combined with low energy consumption.

Signal-to-Noise Ratio

The general goal in telecommunications is the transmission of information by sending a signal from the transmitter to the receiver with as little interference as possible. A relevant factor here is the signal-to-noise ratio: the greater the ratio, the more distinct the difference between the signal and interfering influences—such as overlapping ambient noise—becomes, allowing the information to be received more clearly. There are two ways to minimize these signal impairments: One approach involves reducing or filtering out the interfering factors. The other classic method involves amplifying the signal carrying the information. In both cases, the signal-to-noise ratio is increased and the desired signal becomes clearer.

It should be noted that, depending on the level of amplification, power consumption—and thus energy requirements—increases. Consequently, this factor must be considered, particularly in applications where energy is very limited. Depending on the application area, it is therefore a matter of weighing which approach appears more suitable. Adapting to circumstances and problem-solving is a fundamental engineering skill that also comes into play in the field of communications engineering.

Between Efficiency and Signal Interference

For specific applications, minimizing the energy consumption compulsory for data transmission is necessary, which requires finding tailored technical solutions. One such case is the control of rovers in extraterrestrial environments, but there are also far more telluric environments. In his inaugural lecture, Professor Ralf Martin Kramer presented a new approach to data transmission that meets the specific requirements of data transfer with minimal energy consumption; this topic was also the focus of his dissertation. Since October 2024, Dr.-Ing. Kramer has held the professorship in “Electronic Circuits” at the faculty of Electrical Engineering at Schmalkalden University of Applied Sciences.

Let us first focus on information transmission: To ensure secure information transmission without excessive energy consumption, the transmitter and receiver can agree on specific sequences. This means that the signals consist not only of individual pieces of information but of character strings that then represent a piece of information. One example is the NATO alphabet, in which “Charly” stands for “C”: even if only “arly” were received, it would still be clear that “C” is meant. While this is unnecessary overhead—that is, an additional informational burden—it is a way to improve transmission in cases of disrupted signals and missing fragments. Thus, a certain degree of noise can be tolerated; at the same time, however, a certain amount of computational power is required to interpret the input, as is knowledge of the coding scheme on both the receiver’s and transmitter’s ends.

Radio Frequency Identification

Another variant is Sigma Shift Keying (SSK), which we will turn to soon. In short, this is a transmission technique based on and varying aspects of RFID. What is RFID? Essentially, this stands for Radio Frequency Identification and is a technology for the automatic, contactless identification of objects using radio waves. In addition to a reader, the system includes a transceiver (tag) and simultaneously enables the unique authentication of the tag. RFID tags are widely used, very cost-effective—at least in their passive version—and allow for the unique identification of objects.

There are various variants, though the basic function remains the same: The reader generates a high-frequency field, thereby activating the tag. Depending on the type, the tag may only return information about its presence for identification purposes, transmit additional data, or receive data sent by the reader. The tag can be passive, meaning it has no power source of its own, in which case it draws its energy from the reader’s field. Due to this limitation, the functional scope of these tags is limited. Active tags are equipped with a battery, allowing them to be fitted with efficient sensors whose measurements they can transmit to the reader, for example. Additionally, they can perform calculations independently.

Software-Defined Radio

Before we move on to SSK, we must introduce a second technological component that forms another foundation of SSK: software-defined radio. In short, this is a communication system using radio waves in which the analog hardware has been replaced by software running on an integrated computer. Components of analog signal processing that were previously hardware-based, such as selection and modulation/demodulation, are now handled via digital signal processing. This is made possible by the increased processing power of modern chips. For now, software solutions offer the major advantage of lasting flexibility and adaptability, which fixed, analog systems cannot provide. For example, this is a fundamental aspect of mobile telephony: the constant switching from one radio cell to another and the resulting changes in radio protocols (rules, syntax, semantics, and synchronization of data exchange) would be virtually impossible to implement with analog equipment.

With the latest technological leaps in computing power and the availability of cost-effective components such as digital signal processors, SDR technology has also become widespread in the non-military sector. One example is DVBT receivers in USB sticks, which incorporate SDR components. How does SSK utilize SDR? The SSK requires certain mathematical models and calculations to detect and synchronize the signals. However, these operations can be reduced to algorithms and stored on the receivers in the form of software. As a result, the SSK system remains as lightweight as possible and adaptable to various application fields and computational models.

Sigma Shift Keying

In natural environments, there is an unavoidable background noise. This noise is a true stochastic variable, i.e., a random process that, as such, cannot be predicted. Unlike in standard communications engineering, this noise is accepted in SSK and set, for example, as the binary zero. The second binary state “1,” necessary for transmission, is induced by a targeted modification of the noise. This allows for the addition of extra noise or, alternatively, a reduction of the existing noise. In both cases, the distinguishability of the two signals—that is, the background noise and the information-carrying signal—is established in terms of noise levels. Thus, even though the stochastic nature of the noise itself remains unpredictable, it can be modified in such a way that it transmits information and can be received by a reader. The noise, which until now has been viewed solely as a problem in communications engineering, can thus be utilized for transmission itself.

Absorption, in particular, offers the advantage of energy efficiency, since no separate field needs to be generated here; instead, an existing one is utilized. This is based on the principle of load modulation, already well-known in measurement technology. In simple terms, energy is absorbed and converted into heat via a resistor. At the same time, this reduces noise, enabling contactless detection of the signal.

The technical complexity of SSK is by no means trivial:  Recovering the binary data from the stochastic noise signal is particularly challenging, as it requires both synchronization and detection. Specific mathematical methods have been developed for both tasks to facilitate the transmission of information. The algorithm must therefore determine the levels of various noise samples and identify where data packets begin and end.

The advantage of SSK lies in cases where contactless transmission of measurement values within enclosed objects is required, particularly when this transmission needs to be sustained over an extended period. Thanks to minimal energy consumption and adapted RFID technology, long-term authentication is possible on the one hand, and on the other hand, the use of efficient sensors already integrated into the microprocessors enables an expansion of functional capabilities. When designed as low-power sensors, this technology is suitable, for example, for specific medical devices that monitor the internal conditions of packages (pressure, temperature, etc.).

Research and Teaching

In addition to further optimizing the technology and processes, a goal of the research is to implement SSK receivers on cost-effective hardware, whereby the reduction in costs should facilitate the future widespread adoption of SSK technology. The practical implementation of SSK in the specific application of RFID is still in an early phase of research. The goal here is to put a cost-effective solution into practice.

In addition to RFID transmission, however, there are several other application areas that differ significantly from this. By enabling a change in the standard deviation (hence the name “Sigma”—for standard deviation), i.e., the modulation of the standard deviation, an existing radio link can, for example, be expanded to include the parameter of standard deviation modulation. In short, this allows additional data to be transmitted over the existing data channel.

However, a professorship involves not only aspects of research but also of teaching, namely the transmission of knowledge and skills. Precisely this creative approach to problem-solving, in the sense of a driving force for innovation, can be interpreted as a bridge between the development of Sigma Shift Keying and the fundamental teaching of core engineering competencies, which is particularly relevant at universities of applied sciences. Theory and practice should thus be productively linked to strengthen students’ problem-solving skills. One approach to teaching involves ambitious student projects that combine mechanical and electrical engineering tasks. An example is the design of a sorting machine, for which different groups have found very different ways of implementation. Students can then apply such practical experience in their professional lives.

SUAS Premier: A festive certificate presentation ceremony at W.AG in Geisa

SUAS Premier: A festive certificate presentation ceremony at W.AG in Geisa

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At the end of last year, the final certificates were presented to the participants of the SUAS Premier program in a festive ceremony at the premises of W.AG in Geisa. Ten young people from a wide variety of countries celebrated their successful completion of the SUAS Premier program.[1] SUAS Premier is a project at Schmalkalden University of Applied Sciences funded by the Federal Ministry of Education and Research and the DAAD (German Academic Exchange Service) as part of the ProfiPlus program, which aims to integrate international students into the Thuringian labor market.

The general aim of the program is to keep highly qualified international graduates from the university in the region and to facilitate their entry into professional life. We are already facing the challenge of a shortage of skilled workers, and the problem is set to become even more acute in the foreseeable future, with a good half of all skilled workers leaving the German labor market by 2030. In view of this emerging need, the DAAD decided to pursue the promising approach of actively promoting the integration of international graduates into the skilled labor market. One of the resulting individual projects is the SUAS Premier Program, which is coordinated by Jayabadhrinath Krushnan, a graduate of HSM.

This program focuses directly on international students and attempts to provide them with adaptive qualifications for entering the workforce through an intensive, modular training program. To this end, the specific barriers faced by graduates were identified and a short course format was developed to meet these needs, with the aim of retaining skilled workers in the region and bringing well-trained graduates of STEM courses to small and medium-sized enterprises in the South Thuringia region. Based on surveys of local companies, international skilled workers generally lack the necessary technical and language skills, which are precisely what the SUAS PREMIER program teaches in order to close the gap.

The program

In addition to an application-oriented approach in the sense of practical problem-solving skills, the focus is primarily on communication, i.e., the teaching of language skills. Even though the use of English is certainly increasing in Thuringia, a basic knowledge of German is essential for entering the job market in southern Thuringia, which is dominated by small and medium-sized enterprises.

The first module deals with teaching basic professional STEM skills, serves to build general competence, and at the same time has a strong focus on practical application. It is precisely the concrete experience in doing and problem-solving that international graduates of STEM programs often lack for a successful start to their professional lives : In other words, it is about the hands-on mentality and corresponding experience that students already have to some extent, but whose profile needs to be sharpened. The technical program is carried out in cooperation with the HSM robotics laboratory and the corporate partner Mehnert Lab in Erfurt. The second module is based on teaching language skills and a general understanding of the local work culture. The third and final module aims to equip graduates with knowledge of the regional job market in the STEM sector and ultimately enable them to recognize and seize opportunities.

At the end of this challenging learning process, which participants must complete alongside their studies, successful graduates are presented with their certificates in a formal ceremony honoring their achievements. In order to emphasize the connection to the local economy, the awarding of the certificates is combined with a company visit: This time, the visit was to W.AG, a company based in Geisa, located in the southern Wartburgkreis district.

The company

The company fits the now almost proverbial description of a “hidden champion,” although this would not be expected at first glance given its field of activity: the manufacture of innovative plastic cases in the B2B sector, i.e., business to business. These are customized, individual transport or storage solutions, such as those required by the automotive industry for certain tools.

The exciting question is how the company from the Rhön region has managed to survive alongside competition from the Far East. Ultimately, the reason for its success is a combination of innovation, professionalism, and flexibility. The relatively small quantities produced are fundamental to the concept: customized solutions that remain adaptable and can be produced quickly. One factor contributing to speed is the short transport distances on site – even the tools can be repaired at the Geisa location.

The innovativeness is evident, among other things, in the three lines of related materials: in addition to classic pure polypropylene, there is a choice between the ORGANICLINE, which meets sustainability standards and is entitled to carry the EU Green Brand seal of approval, and the CIRCLELINE, which uses recycled materials, i.e., processed, recycled plastic, and is also committed to sustainability. In addition to a wide range of models and color options, customers now have three more options to choose from when customizing their suitcases.

The graduates were able to get a taste of a company that, like many others, is looking for well-trained specialists. The SUAS Premier Program is designed to help reduce the difficulties international students face when entering the job market and to provide  companies with a pool of skilled workers that has been underutilized until now. 

[1] Two additional certificates were sent to participants who were unable to attend due to scheduling conflicts.

Tough times, tougher engineers. How toolmaking is dealing with current challenges

Tough times, tougher engineers. How toolmaking is dealing with current challenges

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Toolmaking covers a wide and diverse range, including tool development, manufacturing, and use. The design and manufacture of precise and complex tools with high performance and durability is a cornerstone of modern industry, and the current crises are affecting both mechanical engineering in general and toolmaking in particular.

Starting with the design of special cutting tools (e.g., milling tools or drills) and the application of coatings, toolmaking also deals with customized production processes and the reconditioning of tools. Without being the center of attention itself, toolmaking plays a relevant role in improving people’s everyday lives, whether through the manufacture of household appliances, the expansion of the technical infrastructure of our mobility (in addition to automobiles, trains, among other things), or the development of forward-looking technologies in microelectronics and space travel.

The Schmalkalden Tool Conference, organized by the GFE (Gesellschaft für Fertigungstechnik und Entwicklung Schmalkalden e.V.) in cooperation with the Schmalkalden University of Applied Sciences and the VDMA (German Engineering Federation). Renowned companies and research institutions not only provided insights into approaches to technological development and experiences in their application, but also focused on how to deal with these challenging times.

The motto of this year’s biennial conference was “Resource-efficient & economical tool development, manufacturing, and use,” focusing on the productive combination of ecological sustainability, technological efficiency, and economic optimization. Despite their different emphases, all three aspects can be positively combined and motivate each other, thus helping toolmakers to find robust answers to the questions and tasks of the present.

External influences: International raw material markets and bureaucracies

One current challenge facing tool manufacturers is the availability of raw materials such as tungsten, which form the basis of carbide tools. Their distribution on the European market is currently very limited, and prices have skyrocketed in some cases over the last six months: Not only has China restricted exports of these metals, it is also buying up the remaining raw materials on the global markets on a massive scale. This has resulted in shortages and increased costs. This trend is even evident in scrap metal, which is also being skimmed off the European market by higher price offers from China via . One response from the industry is to secure its own sources of raw materials, to pursue recycling even more vigorously, and to keep scrap metal as a valuable raw material on the European market, because the short-term losses in sales price are justified by medium and long-term advantages. At the same time, the goal must be to use scarce resources efficiently, which in turn gives momentum to approaches for recycling tools and their sustainable, optimal use, as was also made clear at the tool conference.

Like many other industries, toolmaking is also burdened by bureaucratic obstacles, which is a second external factor. In addition to the national level, there is also the transnational level of the European Union, which, in the concrete experience of toolmaking, leads to a confusing jumble of different actors and legal regulations that is almost impossible to navigate. For example, the import of raw materials often involves complex tasks with different documentation requirements. Another issue is the decreasing time horizon for policy decisions: industrial transformation processes require long-term perspectives and the certainty that investments will pay off. The policy framework therefore lacks a regulatory orientation, which in turn is central to setting innovative impulses.

One response to restrictive regulations is research and development: if the EU bans the use of lead in materials such as aluminum, then an adequate substitute must be found. First, the effect of lead as a component and in processing had to be understood: in short, lead has a positive influence as a plasticizer and lubricant in processing, particularly with regard to the ideal of producing many small chips during milling. If it is removed from the material, the result is reduced chip breakage during machining processes, which in turn leads to long, tangled chips that clog the machine, stop the production process, and are difficult to remove. One way forward would be to adapt the tools, for example by changing their geometry, in order to promote chip breakage and make the use of lead-reduced alloys such as brass feasible. This could therefore be an alternative that meets production standards, although the parameters of usability and scalability on an industrial production scale still need to be examined.

The elective affinity of efficiency and ecology

Another answer is to further optimize tool manufacturing processes, which has always been a motive for tool production. There are various approaches to this: one possibility presented at the conference is simulation-based milling tool development. This optimization guarantees the quality of production and minimizes tool wear at the same time. Such an approach uses so-called gray box models to predict tool wear and maximize tool life. An abstract physical model (white box) is combined with a model trained on real sensor data (black box) to estimate the ideal point of wear. Efficient use of the tools minimizes the amount of material and energy required.

Another option is to build tools in a modular fashion so that, when wear and tear occurs, only those parts that have actually become unusable need to be replaced. As with many applications, the implementation of sustainability principles must be considered as early as the tool design stage. Which parts are most likely to need replacement, where can a tool be sensibly divided, etc.? Ideally, sustainable tool use would be based on the principles of “recycle, reduce, reuse,” which was also the title of a presentation at the tool conference.

Last but not least, artificial intelligence was, as expected, a topic that is driving the industry. It is important to note that this is neither a buzzword nor a promise of salvation, but rather a tool that, when used in the right place and in the right way, can offer advantages, including in the evaluation of data and the subsequent optimization of manufacturing processes. Just as in the case of additive manufacturing, experience in dealing with this technology is needed to determine its advantages and disadvantages in concrete terms. Here, the industry is still searching for the ideal fit for AI-supported technologies.

Space and the vacuum. Innovation and outlook

Two presentations provided impetus with regard to specific fields of application: Spaceoptix, a company based in Jena and spun off from Fraunhofer IOF, is involved in the development, manufacture, and integration of high-precision metal optics and mirror systems, which are used in satellite communications, among other things. These areas of application place high demands on manufacturing processes (CNC milling, turning, and polishing, among others) and the tools used. One specific research project in which Spaceoptix is involved is satellite-assisted monitoring of the water supply for agricultural land.

The second impetus came from VACOM, a company that has found a unique selling point in vacuum technology for applications in research and industry and works for partners in aerospace technology and coating processes, among other areas. The manufacture of high-purity components and the cleaning of components is a growing field that is currently being exploited by cutting-edge technologies: For example, the manufacture of state-of-the-art computer chips using EUV lithography – the abbreviation stands for extreme ultraviolet light – requires not only the highest quality components, but also a high degree of surface cleanliness for all components. The manufacture and subsequent cleaning of components for the semiconductor industry, in turn, sets high standards for manufacturing processes.

Cutting-edge technology requires skilled professionals who are well-versed in research and application: in addition to companies such as VACOM, which are firmly committed to training, the development of young talent is also a task for universities. Tomorrow’s skilled workers are trained at universities of applied sciences such as the University of Applied Sciences Schmalkalden, where the focus is not only on theoretical knowledge but also on teaching practical skills. This is also evident in the tandem professorship of Andreas Wirtz, who works equally at GFE and HSM: As head of the “Cutting Tools & Technology” division at GFE’s and holder of the professorship for “Manufacturing Technology and Virtual Process Design” at HSM, Professor Wirtz can combine the experience of both worlds to the benefit of his research and teaching. In addition to the tool conference, it is Andreas Wirtz’s tandem professorship that demonstrates the possibilities for trusting cooperation between science and industry.

Help in unfamiliar territory. How therapies for post-COVID are being developed

Help in unfamiliar territory. How therapies for post-COVID are being developed

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Although the massive disruptions to everyday life have noticeably decreased, the individual and societal burdens resulting from the coronavirus pandemic are still palpable. Post-COVID syndrome is now recognized as a clinical condition, and improving diagnosis, prevention, and treatment are driving medical research. Professor Thomas Urban, in collaboration with the Post-COVID Center in Senftenberg, developed a specific therapy concept for post-COVID-19 patients and presented his approaches, methodology, and some results in a report on his past research semester, which are also central topics of his second habilitation thesis.

Applied science in the medical field had already distinguished itself at the beginning of the pandemic through the immensely rapid development and provision of various effective vaccines and their continuous adaptation to different variants. Without these achievements in research and production by pharmaceutical institutions and companies, the consequences of COVID-19 would certainly have been far more drastic and protracted. The response to the pandemic highlights the innovative potential of application-oriented medical research and health tech, which combines state-of-the-art technologies with a focus on the physical and mental well-being of patients.

Research in progress

However, research in this area is by no means complete: on the one hand, there are always new variants of the virus and thus the need to adapt vaccines to continue to effectively protect vulnerable groups. On the other hand, medical development must address the physical and psychological effects of the pandemic. As with the development of vaccines, the novelty of the pathogen poses challenges for research, as the first step must be to understand the clinical picture itself and characterize its various manifestations. This foundation can then be followed by considerations of therapeutic measures.

Post-COVID syndrome is now a recognized clinical picture and is receiving widespread public attention, precisely because the long-term effects of COVID-19 affect quite a few people and burden them in their everyday lives. Even though the two phenomena are colloquially used synonymously, long COVID refers to persistent impairments lasting more than four weeks up to three months after infection, and post-COVID refers to the subsequent period.[1]

Similar to other infectious diseases, a coronavirus infection (SARS-CoV-2) can result in a variety of long-term effects that can impair organ systems such as the heart, lungs, brain, and other organs over a longer period of time. Long-term here refers to persistent symptoms twelve weeks after the actual infection, with the frequency of occurrence varying between 10% and 20%. The causative factors currently under discussion are overactivation of the immune system and thrombus formation in the microvascular system.[2] The consequences for humans are wide-ranging, from exhaustion (fatigue[3] ) to cardiovascular problems and balance disorders to nerve damage and persistent pain. This variance suggests the complexity of the syndrome, both in terms of its medical description and causal localization on the one hand, and therapeutic approaches on the other, whereby various disciplines of medicine must cooperate. In addition to alleviating symptoms, the goal of therapy is to prevent the condition from becoming chronic and to enable those affected to participate in their private and professional lives.

The blended therapy approach

An innovative therapeutic approach is suitable for this multidisciplinary approach, which Professor Urban analyzed during his research semester and was also able to empirically investigate at a coronavirus therapy center. The chosen approach is called blended therapy and combines classic analog and digital forms of therapy. The digital supplement enables more flexible treatment that is less restricted in terms of space and time, allowing for continuous therapeutic forms and individual implementation of medical recommendations. For example, mobile apps and smart watches allow automated, close (self-)monitoring, while special monitor camera systems allow exercises to be monitored at home and controlled in real time. Research into these therapeutic approaches is also necessary because there are currently few specific cross-sectoral concepts and, to date, no therapeutic approach for post-COVID has been recommended as standard that addresses the causes of the condition, as opposed to approaches focused on symptom relief, and that has been tested according to empirical criteria.

Based on the S2k guidelines of the German Society of Neurology and the LMU’s post-COVID care concept, a therapy was developed that takes into account the specific needs of post-COVID patients on the one hand, but on the other hand places a certain amount of strain on patients. This was rather unusual in previous post-corona therapies.[4] One consequence of the impaired energy balance is possible spontaneous collapses (post-exertional malaise), which patients could not foresee and which set back the convalescence process immensely. [5]At the same time, therapy methods that use forms of stress and avoid overexertion through controlled conditions have proven to be quite successful. Individualized energy management and the minimization of overload were important factors in the therapeutic approaches.

Blended therapy combines traditional in-person treatment with digital intervention tools, offering the possibility of real-time analysis of stress, performance, and energy expenditure in patients during exercises (including at home). Instead of comprehensive rest, sensorimotor limitations and fatigue were addressed with balance training and motor exercise therapies. Subsequently, cognitive behavioral therapy designed for fatigue was implemented, which also focused on secondary psychosomatic symptoms and the assessment of the subjective effectiveness of the training therapy.

Study and evaluation

The accompanying study took place over a three-year period at the Corona Therapy Center Lausitz (Senftenberg). In addition to changes in the main symptoms, general effects on physical and mental health as well as secondary effects had to be taken into account. The study included 407 patients who met certain criteria. The training sessions took place both in person and at the patients’ homes, which allowed the required exercise intensity to be achieved. The second phase was accompanied by a survey study to gain important insights into the benefits of therapeutic measures in the context of healthcare.

Prof. Dr. Thomas Urban at the Medical Conference at Brandenburg University of Technology Cottbus–Senftenberg on March 12, 2016

The evaluation of the therapy was based on two criteria: the main post-COVID symptoms and the motor fatigability parameters, the latter providing an indicator of mobility. In general, positive effects were observed in terms of both the main symptoms and the motor and cognitive fatigability parameters.[6] In the end, positive therapeutic effects were detected, as was the benefit of the blended therapy approach, which can also be integrated into the existing healthcare system. Not least, the therapy enabled those affected to learn to cope with their reduced energy levels while making effective use of their remaining capacities. This is an important first step in offering patients the chance to actively participate in social or professional life again.

Professor Urban submitted his postdoctoral thesis entitled “Sektorenübergreifende beanspruchungsgesteuerte multimodale Blended Therapy für Post-COVID-19-Patienten mit Fatigue und sensomotorischer Instabilität” to the Department of Healthcare Science at the Institute for Medical Technology at the Brandenburg University of Technology Cottbus-Senftenberg.

[1] See Urban 2025, Sektorenübergreifende beanspruchungsgesteuerte multimodale Blended Therapy für Post-COVID-19-Patienten mit Fatigue und sensomotorischer Instabilität, pp. 10–24, (manuscript) and https://www.kvberlin.de/fuer-praxen/aktuelles/themen/thema/long-covid.

[2] See Urban, Thomas et al., Fatigue und sensomotorische Instabilität. Neurologisch kontrollierte Konversion von Post-COVID-19-Patienten, in: Nervenarzt (2024:95, pp. 1104–1115), p. 1107

[3] “Fatigue is characterized by physical (especially motor), cognitive, and/or mental exhaustion that is often subjectively severely limiting, disproportionate to the preceding exertion, and cannot be alleviated by sleep.” (See ibid., p. 1106) Another characteristic is the unpredictable onset of exhaustion, which in turn affects the individual’s energy balance.

[4] In cases of energy depletion, fatigue, and similar conditions, it was generally recommended that those affected take it easy.

[5] The stress reactions can in turn be somatic, cognitive, and also emotional in nature. One problem in avoiding crashes is that there is no proportionality between actual stress and the triggering of breakdowns. Technical possibilities allow stress to be controlled in real time, which in turn helps to avoid breakdowns. (See ibid., p. 1110)

[6] Without going into the details of the evaluation here, it is important to point out a problem that highlights the challenges of therapeutic approaches. Women experienced a worsening of secondary psychosomatic symptoms: one explanation for this is the faster course of therapy in men and the resulting longer stress in women, overconfidence, and evasive behavior, especially in young women. Therapies must understand these particularities and take them into account in their treatments in order not to jeopardize other successes.

Panta rhei. Materials science and its view of the dynamics of the world

Panta rhei. Materials science and its view of the dynamics of the world

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Heraclitus’ Greek aphorism, according to which everything flows, takes on additional significance in the field of materials science. The principle of eternal becoming and change can be translated here as meaning that nothing is truly fixed and, contrary to expectations, some things are not really sharply separated. This is a unique perspective on the structure of materials and their relationships, on the interplay between substances and things. And what all this has to do with the production of modern microchips, which are found in our smartphones and smartwatches, will be discussed on the following pages.

At first, it makes sense to introduce the subject itself: Materials science is a discipline that lies between chemistry, physics, and engineering, linking these fields in a unique perspective. It is therefore an interdisciplinary field that deals with the research, development, and application of materials. As a science that focuses on materials, it aims to understand mixtures of substances, their interactions, and the resulting properties. It deals with chemical descriptions as well as physical, chemical, and mechanical characterizations, analyses of the structures and composition of substances, and the manufacturing conditions described by factors of thermodynamics and kinetics. The focus is therefore on thermodynamic and kinetic fundamentals for materials that are important in engineering:  approaches are developed through the creation of phase diagrams, the investigation of diffusion processes, and the characterization of internal interfaces.

Furthermore, one subfield of materials science deals with the development of new or adapted materials with specific properties that are tailored to the requirements of certain applications. When we think of the highly specialized materials used in modern microelectronics, for example, which form the basis for miniaturization and increased performance, it becomes clear how materials science taps into innovative potential through its combination of natural science and engineering approaches. This also demonstrates the bridge between basic research and its transfer into application-oriented reality, which is particularly important as a productive link between research and development for universities of applied sciences. 

How do materials scientists work?

Phase diagrams, i.e., representations of phase transitions as a function of various parameters, are useful for understanding the properties of substances and how they change in different states. In these diagrams, phase transitions (from solid to liquid to gas, etc.) are represented by influencing factors such as composition and temperature. The substances or individual components have different relevant properties depending on their state and, among other things, during the transitions, which need to be characterized. These diagrams can be used to investigate thermodynamic and kinetic behavior, which can then be used specifically in manufacturing processes, for example.

Another aspect within materials science is diffusion, i.e., the interactions between substances, for example, between two metal layers. Our everyday understanding suggests that there are no interactions between the two metals, as both are solid bodies that exist completely separately. However, if we use low-scale observation methods such as electron microscopes, in which the atoms and atomic lattices become visible, the picture changes: to stay with our example, relationships can exist between the metals, which can lead, among other things, to mutual mixing or even to the incorporation of one substance by the other. When different metals and alloys are combined, as in microchip manufacturing in electrical engineering, such effects must be taken into account, which is the focus of materials science.

The investigation of such interdiffusion processes is one aspect of materials science that leads us to Martin Seyring and his research at Schmalkalden University of Applied Sciences. Dr. Martin Seyring joined HSM in October 2022 as a research assistant for scanning electron and optical microscopy at the Faculty of Electrical Engineering. Previously, he researched and taught at Friedrich Schiller University in Jena, where he also earned his doctorate.

Materials science research at HSM

Martin Seyring’s research focuses on phase imbalances at metallic interfaces, which in the field of materials science encompasses processes such as interdiffusion. At HSM, he works with Roy Knechtel, who holds the professorship for Autonomous Intelligent Systems. Both are now conducting research into the development of microelectronic components, known as MEMS. Among other things, this involves pressure, acceleration, rotation rate, infrared radiation, and tilt sensors, which form the technological basis of our modern devices such as smartphones and smartwatches. While Roy Knechtel focuses on the microelectronic design and integration of the sensors, Martin Seyring is dedicated to the integration of the sensors, which is achieved through processes such as bonding and soldering, for example, thus contributing his experience in the metallurgical field of materials science. In order to advance the goal of achieving ever higher integration densities and realizing smaller, more efficient, and more powerful components, the related materials and their complex relationships are increasingly coming into focus.

One goal is to maximize the technical potential when connecting the tiny structures on and with the silicon wafer. Of course, there is not just one bonding process, but various methods that are suitable for different applications. In addition to anodic bonding and, for example, glass frit bonding, metals or alloys can also be used for bonding in metallic bonding, and this is where Martin Seyring’s research and his experience with metallic materials and the behavior of thin films come into play. What are the relationships between the individual metal layers—some of which are created during bonding, soldering, and coating—and how can these be optimized in various ways?

An important aspect of the interactions is time: diffusion and chemical reactions sometimes proceed very slowly, but their consequences are significant.  Naturally, temperature is a factor that accelerates both of these processes. This also presents an opportunity for research: by controlled increases in temperature, a longer period of time can be simulated and the effects on the materials studied. This makes it possible to answer questions such as how hot components can become or how thin the related layers can be, which is particularly relevant from the perspective of efficient high-volume production.

Where technology and ecology meet

Sustainability is an important aspect that leads us neatly to a current research project by Martin Seyring and Roy Knechtel. The title of the project is MatInWLP, which stands for material innovations in wafer-level packaging. Once again, the topics we have discussed so far come together in a new context. In addition to the focus on materials, WLP is at the center of attention: This refers to the attempt to apply the components directly to the wafer, thereby eliminating many individual process steps. In other words, with WLP, the steps involved in building semiconductor chips into usable components take place simultaneously and directly at the wafer level, including the steps of encapsulation and contacting. This project also addresses innovative 3D printing technologies that could play a role in WLP.

To understand the innovative nature of this technology, it is important to consider the current state of chip production: despite or regardless of the enormous increase in the quantity – as well as the quality – of microelectronic components produced, their manufacture still involves an immense logistical effort. The components travel around the globe for the many individual manufacturing steps, leaving a significant ecological footprint. Furthermore, the sometimes sensitive origins of related materials such as cobalt must be taken into account: the trend toward ever greater miniaturization is offset in terms of material consumption by the sheer mass of chips produced. The MatInWLP project combines technological and ecological ambitions: on the one hand, it involves the technical realization of direct integration of the components on the wafer, which is challenging enough in itself. On the other hand, it involves an attempt to minimize not only transport costs but also material usage through direct bundling on the wafer, thereby further reducing the ecological follow-up costs.

The MatInWLP research project is funded by the Carl Zeiss Foundation, which recognizes the technological, economic, and ecological potential of optimizing manufacturing processes and material combinations. Added to this are the advantages of applied sciences, such as their practical orientation, which places particular emphasis on the implementation of the knowledge gained. The project will run until early 2027 and has been awarded €1,000,000 in funding.

The Assistant Excursion (AssEx) 2025: exchange, insights and new perspectives

The Assistant Excursion (AssEx) 2025: exchange, insights and new perspectives

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Every two years, a joint excursion for research assistants and doctoral students at Schmalkalden University of Applied Sciences takes place, organized by the Vice President Research and Transfer and Ms Sandy Korb, Head of Department D2. Two years ago, the so-called AssEx went to Nuremberg in Middle Franconia, but this time it was to Würzburg in Lower Franconia.

The aim of the assistant excursion is to promote interdisciplinary exchange between young academics at our university. As part of the event, the participants presented their research projects and the topics of their doctoral projects and discussed these in an interdisciplinary manner. The academic program was supplemented by informal discussion rounds in which challenges in the day-to-day work of a doctorate were openly addressed and valuable experiences were shared in an atmosphere of trust.

A central element of the excursion is also a visit to a company. To kick off this year’s AssEx, Brose Fahrzeugteile SE & Co. KG opened its doors at the Würzburg site. The automotive supplier develops and manufactures electric motors for transmissions, steering and air conditioning as well as drives for two-wheelers. The participants were given in-depth insights into the company and its production processes.

With 68 locations in 24 countries, Brose has a broad global presence and remains a family-owned company – a self-image that is reflected both in its mission statement and in its day-to-day work. Brose Würzburg meets the current challenges of the automotive supplier industry with a high degree of innovative strength – not only in terms of products, but also with regard to modern manufacturing technologies, especially in the areas of automation and digitalization.

Three dissertation projects were then presented. The first was Paul Kluth, who is doing his doctorate at the Faculty of Business Law on the subject of location predicates. These are legally relevant terms such as “health resort”, “spa” or “resort”, which are officially recognized by numerous municipalities in Germany. The first task is to describe the phenomenon and put it into a legal context. Even if it is primarily a legal problem in municipal law, the closer you look at it, the more complex the situation becomes. The recognitions under state law are based on laws or ordinances; in practice, the stipulations of associations are of considerable importance. A certain medical-health tourism quality must be present to be awarded the label. Precisely because the labels can be accompanied by special legal consequences with high practical relevance (e.g. in tax law or store opening hours), this creates a legally attractive field of investigation. Thematically, it also fits into the increasingly important discussion on health aspects. A well-founded classification under commercial law is just as much in the interests of the administration as it is in the interests of the economic players concerned.

Yekatarina Strigina is doing her doctorate at the Faculty of Mechanical Engineering and is working on the “RoboTraces” research project, in which she was involved. The project dealt with logistics using micromobiles, which were intended to relieve the burden on older people in particular in their everyday lives by running errands or transporting goods. Moving the robot on sidewalks posed a particular challenge. On the one hand, the uneven terrain and the sometimes poor condition of the paths were difficult for the robot to cope with. Secondly, footpaths are inherently unstructured spaces: they generally have neither clear rules nor markings or unambiguous guidelines, which makes it difficult for autonomous systems to move safely and predictably. Another key task was communication between the robot and its environment, which also includes passers-by. The aim was to determine parameters in this human-machine interaction in order to clarify the conditions for acceptance. Speed, distance and predictability of actions were key factors. The dissertation attempts to integrate decision-making routines into the robot’s reaction patterns, which are fed by an artificial intelligence that has in turn been trained on real behavior and psychological insights. One of the ideas here is posture, which – correctly interpreted – allows conclusions to be drawn about a passer-by’s intentions. The aim is to enable the robot to react quickly, flexibly and reliably to this in its movement sequences. As a large number of autonomous micromobiles will be moving around in public spaces in the foreseeable future, similar projects are needed to proactively counter conflicts on shared paths.

Finally, Lukas Hauck from the Faculty of Electrical Engineering presented the progress of his project since his first presentation at the previous AssEx. In principle, this dissertation is about additive manufacturing of electronic components and exploring the technical possibilities of a 3D integration system: the latter can be described as a machine platform that allows different substrates to be applied to different and inhomogeneous topologies using different processes. In other words, the system offers various technical options for processing (such as dispersion or jetting, i.e. the contactless application of mostly drop-shaped fluids) of very different materials. At the same time, the 5-axis system makes it possible to work not only on a flat plane, but also in 3-dimensional space. This means that electronic components can be produced in positions that were previously difficult or impossible to access. Due to the multitude of possibilities, however, the control and efficient use of the system has also become complex, which poses challenges for prototyping as a field of application for the system. In order to keep the adaptation cycles and finding the optimal technology as minimal as possible, Lukas Hauck attempts to characterize and systematize different technical possibilities, determine different modules and describe possible combinations of different components. These design rules are intended to simplify the handling of the machine platform and exploit the optimum of its technological possibilities.

Finally, Ms. Ludwig reported on the current status of the FH-Personal project with a special focus on the activities in the context of young scientists. For example, the first-ever doctoral website, new impulses in doctoral coaching and current activities in science communication.

The AssEx was rounded off with an evening together and a tour of the city. The informal exchange that accompanies such an evening serves to share experiences of this special phase of an academic career: in addition to research topics, it is also about career planning strategies or very human questions of work-life balance, for example.

As the doctoral students are at least in a similar situation, events such as the AssEx bring together people who can discuss such issues without barriers.

Does GenZ tick differently? An empirical examination of generational differences

Does GenZ tick differently? An empirical examination of generational differences

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For a few years now, there has been an increase in journalistic articles in which the supposed deficits of the GenZ, from general values to specific work ethics, have been addressed. People in this age cohort, roughly those born between 1995 and 2010, are accused of being lazy, leisure-oriented and lacking ambition, among other things. The question of how the GenZ’s attitudes to work and their expectations of their working conditions differ from those of previous generations and whether these differences stand up to scientific scrutiny is an open research question. Professor Katharina Sachse, in collaboration with Claus-Peter Heinrich, Silke F. Heiss and Sandra Sülzenbrück, has investigated this question as part of a recently published study entitled “Employer attractiveness from the perspective of the generations. Unity instead of differences”.

The term “generation” is vague and is used differently in science and everyday life. Although many people feel that they belong to a generation, it remains unclear what actually holds this unit together.

Youth researcher Jürgen Zinnecker distinguishes between three perspectives:

  1. Birth cohorts – people born in the same time period.
  2. Life stages – such as grandparents, parents and children, who are characterized by different life situations.
  3. Contemporary historical events – defining moments such as 9/11 or the introduction of the iPhone.

All three approaches show that “generation” can mean different things. Ultimately, the concept of generation should not be understood as a fixed boundary, but as a tool to make changes between groups visible.

It is important to note that different disciplines use the term differently: Pedagogy, sociology or historiography each set their own accents. The term remains useful above all to describe how people place themselves and others in their time. In the HR departments of companies, generational classifications are sometimes used to align specific personnel measures. Business psychology sheds scientific light on how employees can be recruited and retained, and also examines whether the often-discussed differences between generations – for example in GenZ – can actually be proven.

GenZ: Between crises and criticism

And that brings us to GenZ, whose youth and young adult life was primarily characterized by crises, from the euro crisis and the “refugee” crisis to the pandemic and its consequences and finally the Ukraine “crisis”. (Cf. Katharina Sache et al, Arbeitgeberattraktivität aus Sicht der Generationen. Einigkeit statt Unterschiede, Berlin 2025, p.12) The increasing digitalization of everyday life, social life and communication should also have an impact on this generation’s understanding and relationship to the world. Even if the childhood and youth of the GenZ were shaped by special circumstances and certain effects on this generation are therefore plausible, the criticism of the work ethic of this generation noted at the beginning is based less on soft attitude variants than on fixed, tangible differences in the value system of the GenZ that separate them from other cohorts. The concept of generation is not used here in the sense of an exploration of soft differences in attitude, but as an attribution of tangible, overarching characteristics of an age group.

The criticism is primarily aimed at the subject area of work and can be divided into the individual work ethic and the demands of the people concerned on their employers. For example: WirtschaftsWoche headlines that GenZ would rather be unemployed than unhappy. Deutschlandfunk Nova states a high willingness to change jobs or employers, RP online asks about excessive sensitivity in professional life. The press portal reports on GenZ’s immense salary expectations, while Focus sees a lack of willingness to work overtime. ZDF presenter Lanz prominently criticized the post-material values of GenZ and their search for the ideal work-life balance. In addition to articles and books about GenZ, there are numerous videos on platforms such as YouTube. Aside from critical impulses, the focus is often on advice for companies and HR managers.

The evidence-based review

The question arises not only as to whether these descriptions of Generation Z are at all accurate, but also whether the normative changes, for example in the demands of a work-life balance, are an effect limited to this generation or rather mark a socio-cultural shift encompassing all generations in the spirit of the times. In an empirical study, Katharina Sachse’s research group investigated the question of whether the claimed differences between the generations stand up to scrutiny.

According to a popular distinction of generations into cohorts, Baby Boomers, Generation X, Y (Millenials) and Z can be separated and characterized by more or less rough attributions. From the point of view of companies that perceive they are in an increasingly competitive market for skilled workers, these profiles are important, as they can supposedly maximize recruitment opportunities and minimize fluctuation risks by taking them into account. The assumption that security is important for the motivation of older employees and self-fulfilment in the workplace for younger generations could be used to generate tailor-made job profiles and job conditions. (Cf. Sachse et al. 2025, p.09f.)

The question now is whether the fundamental thesis of a tangible difference between the generations and their weighting of employer attractiveness factors is even true. The research situation on GenZ is still thin, because there can hardly be any reliable studies for the sole reason that GenZ has only recently entered the labor market and been able to gain experience. International studies that generally focus on generational differences have not yet been able to identify any serious differences between the generations. (See Sachse et al. 2025, p. 17f.)

The aim of the study by Professor Sachse and her research team was, on the one hand, to provide an empirical study using Germany as an example and, on the other, to provide a focus on attitudes towards employers.[1] The evaluation of the survey was based on data from 1133 working people, with all generations represented in roughly equal numbers.

The survey examined various employer attractiveness factors in 68 items along 19 dimensions. A regression analysis of the data revealed that both instrumental (income, security, benefits, etc.) and symbolic characteristics (social and altruistic values as well as status, i.e. prestige and authority, etc.) are relevant for employer attractiveness. The weighting of the factors does not differ significantly between the generations. Above all, there are no differences between the generations in the most important characteristics such as identification with the employer, leadership and work tasks – these are equally relevant for all. In short, the break between the generations and a distinct character of the GenZ in their work values and expectations cannot be empirically confirmed.

Conclusion: An unnecessary polarization

This does not mean that the attractiveness factors do not change over time. However, a zeitgeist effect that affects all generations sui generis seems to be the decisive factor here. For example, another study found that preferences regarding the length of working hours have generally changed – even baby boomers today pay more attention to work-life balance than in the past.

Tailoring recruitment to Generation Z is therefore unnecessary. Employees at all stages of their careers – from starting a new job through to retirement – should be offered working conditions that suit their needs. This includes good leadership, meaningful activities, appropriate remuneration and work tasks in which employees can use and expand their own skills.

It can be stated that although there are individual generational variances, these are only minimal. Among other things, changes in the zeitgeist and the genuine effects of life stages must always be taken into account when comparing generations. At the beginning of their professional lives, GenZ are in an orientation phase in which they have to gain various experiences in order to find the right employer and career path[2] . This alone explains the differences to members of older generations on the labor market.

In addition to a conceptual sharpness, the term generation also lacks an empirical profile that could be confirmed on the basis of concrete observations: although individual differences can be identified between generations, including in the attractiveness of employer factors and work values, these are too small to serve as a dividing line between the generations. Despite a certain variance, the work values of the generations are close to each other. In short: GenZ is no different.

[1] The design of studies necessarily has an impact on the perspective opened up: in a cross-sectional study, in which all people are surveyed at one point in time, all generations can be depicted, but at the same time the generation cannot be separated from the life stage. At the time of the survey, all members of a generation are the same age and therefore in the same phase of life. Any differences identified between the generations can therefore also be due to age or life stage effects.

[2] The phases of exploration, establishment, maintenance and withdrawal can be separated, whereby each is subject to its own logic and preferences.  (See . Sachse et al. 2025, p. 16)

Endowed professorships as a source of impetus for research using the example of Roy Knechtel

Endowed professorships as a source of impetus for research using the example of Roy Knechtel

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Even though endowed professorships are still quite new structures, they have now become firmly established in the German academic landscape. They offer a genuine advantage that is particularly important from the point of view of research and transfer: endowed professorships take up the innovative potential of technological developments and promote their translation into university institutions. Their number has increased in the recent past, with endowed professorships now accounting for up to 2% of the total number in Germany. Before we turn to a specific example of such an endowed professorship at Schmalkalden University of Applied Sciences, it is important to clarify what distinguishes traditional professorships from endowed professorships.

Unlike traditional professorships, the funding is not provided by the state, but by the respective donor, i.e. institutions, companies or private individuals. In addition, the period of the actual endowed professorship is limited, usually to five, sometimes ten years. In consultation with the universities, the endowed professorship is then usually converted into a traditional professorship, thus ensuring the continuity of research and the expertise acquired. A key advantage of these endowed professorships is that innovative fields of research can be developed using this method: The donors determine the thematic focus of the professorship in consultation with the relevant university committees, and provide the funds for the professorship as well as other material and investment resources (e.g. for laboratory equipment). Through these external initiatives, new topics and areas can be introduced that were previously not part of the established canon.

The attraction of these facilities for universities, apart from the point of reduced costs, largely stems from these impulses for research, as can be seen from Roy Knechtel’s endowed professorship through the Carl Zeiss Foundation at Schmalkalden University of Applied Sciences. This gave the university the opportunity to build up expertise and skills in a promising field of research. As the funding period for this endowed professorship recently came to an end, now is a good time to take stock.

Opportunities and challenges

On the one hand, newly appointed professors are usually faced with the task of having to determine the direction of their chair in research and teaching based on their interests and ideas. In addition to personnel and technology, this also includes defining thematic priorities. On the other hand, the chairs usually already exist, which means that there is a certain framework and a stock of existing personnel as well as research and teaching resources. In contrast to these continuations of traditional professorships, it is a characteristic of endowed professorships that they are newly established and not linked to an existing chair, which offers opportunities but also poses challenges.

At Schmalkalden University of Applied Sciences, Roy Knechtel was appointed to the “Autonomous Intelligent Sensor Technology” research professorship funded by the Carl Zeiss Foundation in April 2019. The professorship was funded for a period of five years and therefore lasted until March 2024. The professorship, which was funded by the Carl Zeiss Foundation as part of a program advertised at, was aimed at an area in which Roy Knechtel had acquired expertise and experience in over twenty years as part of his work at the Erfurt-based company X-FAB: The development of MEMS (Micro Electromechanical Systems) sensor technology.

In addition to smaller projects on sensor applications, a particular focus of his research in recent years has been on technological sub-steps for the realization of sensors and their 3D integration with microelectronics to create complex electronic systems, especially sensor assemblies. It goes without saying that specific systems, laboratories and equipment are required for these research questions. In the best case, these are already available, otherwise the more or less costly path of acquiring them must be taken.

When Roy Knechtel took up his professorship at Schmalkalden University of Applied Sciences, he found a cleanroom laboratory which, in addition to being particle-free, also allowed the ambient conditions such as temperature and humidity to be controlled. This was already a favorable starting point. In addition, the air conditioning technology in the clean room laboratory was modernized by the end of last year. But Roy Knechtel was also able to build on an existing foundation in terms of plant technology: Not only was there a high-temperature oven that can generate up to 800°C for glassing processes of screen printing materials, but also a screen printer and a screen cleaner. In addition to chemical boxes and a wire bonder, microscope technology, including a scanning electron microscope with EDX technology for material analyses and a soldering technology inventory with a hotplate and a semi-automatic soldering station were already available.

Laying the foundations for research

As a result, Roy Knechtel did not have to start from scratch, but was able to concentrate on systems that are central to the new field of research. The new focus on modern integration technologies in microelectronics and microsystems technology, particularly with regard to sensor integration, made it necessary to acquire processing equipment – such as various types of 3D printers – and special analysis technology in the form of microscopes.

The various 3D printers serve as the basis for research. The Anycubic Photon Mono m5s pro enables the 3D printing of plastics using photolithographic means, i.e. light. Special polymers that react to the UV component of light are used for this purpose. A resolution of up to 18.5µm can be achieved in the production of mechanical components, which represents a high level of precision. The Bambulab X1E is a filament 3D printer with various outlet nozzles for printing fine structures. Thanks to its numerous sensors and software applications, precise and fast printing is possible. Another advantage is the processing of up to 5 colors and materials in one print.

The term 3D printer only begins to describe the most important purchase: The KRONOS 15XBT[1] system is more of a 3D integration system that allows many different possibilities of processes and related components to produce electronic components in three dimensions. For example, the 5-axis system enables the use of 10 printing technologies, and furthermore, with 8 supported modules, it offers extensions of imaging processes, pre- and post-processing and result optimization. The system allows the processing of a wide variety of materials with widely differing viscosities and properties on topographically complex substrates. As a result, the range of applications is many times wider: not only can different processes for printing, curing and testing be used and combined simultaneously, but almost anything from electrically conductive pastes and insulating inks to viscous glass can also be printed.

These printing technologies are complemented by classic photolithography, which is the technological basis of modern semiconductor production. Although the newly acquired maskless digital imagesetter MLA100 from Heidelberg Instruments offers a slower working speed, it does not require expensive masks and still enables a resolution of up to one micrometer (one thousandth of a micrometer). In combination with a table-top sputtering system, it can be used to produce metallic microstructures (also as a combination of two metals) with electronic and magnetic functions or as joining systems. The combination with printing processes is the subject of current research.

In order to enable the continuation of an important research field of Roy Knechtel from his time in industry, wafer bonding, i.e. the defined stacking and joining of semiconductor wafers for the realization of three-dimensional substrates and electronic and sensor solutions, a wafer bonder system was procured thanks to special funding from the Carl Zeiss Foundation. This is now being used very intensively. As process control, i.e. analyzing the results, is also very important for wafer bonding, a Scanning Acoustic Microscope (SAM) was loaned by the company PVA Tepla, which has raised research in the field of wafer bonding to an even higher level.

Another area of acquisition is microscopy, which can be used to measure and evaluate process results, among other things. A Zeiss light microscope (LSM 700) uses a laser to reproduce the smallest features. The laser beam moves over the object and scans each point individually using the reflected light. An image is then compiled from this individual information. The microscope can also capture different layers, making it possible to create a three-dimensional model. Finally, the microscope also offers instruments for correcting the imaging.

The other microscope is also from Zeiss: it is an EVO MA15 scanning electron microscope. The objects that this microscope can capture are even smaller. In order to be able to image things the size of a strand of hair, the device does not use light, but electrons. A beam of particles is directed at the materials and the electrons knock out other electrons or bounce off them. An image is then obtained from this information. The microscope’s sharpness of detail is useful when it comes to the surfaces of microchips, for example. The tiny patterns (i.e. micro- and nanostructures) used in the manufacture of these chips can also be captured in this way. The microscope also has the option of energy dispersive X-ray (EDX), which is useful, for example, for analyzing the mixing of two metals to form an alloy. This technology makes it possible to determine which new material is involved.

The team and new challenges

With the successful acquisition of these devices, the next phase can now begin – that of intensive research on and with the devices. Micalea Wenig is a technologically adept research assistant. She ensures the smooth operation of the clean room and the equipment, is now an expert at SAM and conducts her own research. With Lukas Hauck, Roy Knechtel was able to recruit a doctoral student who is working on the 15XBT and investigating whether basic rules can be established for the use of the system with different processes and materials. In addition, Dr. Martin Seyring has joined the team as a research associate who covers an area that is highly relevant to microelectronics: materials science. In order to be able to produce ever smaller and more complex electronic components and circuits, the materials and processes involved are important. In short, a team has now come together that can make the best possible use of the technical possibilities for further research.

This is demonstrated by several research projects with Thuringian industry over the last few years. A current project funded by the Carl Zeiss Foundation has led to a further strengthening of this research group in terms of personnel and expertise (which we will be reporting on soon) and to more than ten scientific publications (reviewed articles in specialist journals and conference papers).

In conclusion, it can be said that the endowed professorship has been implemented as planned: The infrastructural foundations for state-of-the-art research have been created and expanded, an efficient research group has been established that continues to grow and work on relevant projects and has many ideas for new future research. The scientists involved and Schmalkalden University of Applied Sciences would like to express their special thanks to the Carl Zeiss Foundation for its extensive financial support, as well as for further training events such as the networking meeting of the foundation professors it has appointed, which have made this sustainable research development possible.

[1] Printing system 3D electronics integration Co-financed by the European Union as part of the funding program Directive for the Promotion of Research FTI Thuringia Research, project no. 2022 FGI 0019

A clear run for hot melt. What advantages can additively manufactured tools offer in extrusion?

A clear run for hot melt. What advantages can additively manufactured tools offer in extrusion?

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Research at universities of applied sciences is practical and transfer-oriented: The potential of mutual cooperation between science and industry can be clearly seen in research projects such as Extrusion Molds in Additive Manufacturing – ExAM, which Stefan Roth, Professor of Product Development and Design at HSM and part of the Applied Plastics Technology (AKT) team, is currently implementing.

What is it all about? First of all, it makes sense to introduce extrusion as a special process in plastics technology: Basically, extrusion is a way of manufacturing “endless” plastic parts such as pipes and hoses, although the actual method is also used in other contexts, for example in the production of pasta. In short, an extrusion line can be described as an apparatus that liquefies raw materials such as plastics, metals or foodstuffs and presses them through a nozzle – also known as a die – whereby this opening produces the shape of the product. In contrast to other processes, the outlet is continuous, which in turn brings with it specific possibilities, but also challenges. It is important to note that the complexity goes beyond the die and includes process steps such as cooling in addition to the melt. Before we turn our attention to the ExAM research project, which focuses on the advantages of additive manufacturing of tools such as the nozzle, we will first remain with the extrusion process.

The extrusion

As already mentioned, extrusion is not a single machine, but can rather be understood as a system with various parts and stations. Let’s take a brief look at the path of the product: At the beginning is the raw material, i.e. the granulate, which is fed into the extruder via a hopper. This contains a screw that rotates and transports the material to the outlet, mixing, compacting and heating it in the process. The friction of the material generated by the screw movement produces heat, which melts the granulate. This melting process is promoted by heating belts attached to the outside of the system. 

Screws

This creates a melt, which is then kneaded and homogenized by the screw. The melt is then pressed through the nozzle and shaped into the desired form. The result is a basically endless molded part, as we know it, for example, as a cable duct, window profile or film.  The product is then cooled and simultaneously calibrated, whereby the processes differ depending on the characteristics of the product. The task is to avoid deformation caused by the thermoplastic properties of the material during cooling. At the end of the process, the continuous extrudate is cut to length or wound up. 

Optimization approaches

It is important to understand that it is not about a material, a process and a machine that ultimately creates a product, but that various parameters have a decisive influence on the possibilities and limits of the process and the product as well as its quality. For example, both the screw types and their processes (e.g. their rotation) have an impact on the melt: different screw types are suitable depending on the material. There are also variables such as quantity, speed and heat, as well as the role of additives, i.e. additives in addition to the granulate, which in turn have their own properties. All of these components must be coordinated depending on the material and product in order to achieve the most precise and efficient production possible at the end of the process. Especially for products that are typically manufactured by extrusion, the aspects of quantity are central. Due to the high quantities, improvements in production have enormous effects here.

In such fundamental and generalizable areas, joint industrial research is a suitable vehicle for research projects. All participants can benefit from industrial collective research, IGF (Industrielle Gemeinschaftsforschung), projects and their results – without being held back by competitive pressure. In other words, this is an ambitious, pre-competitive cooperation that promotes research for mutual benefit. This community is supported by the Federal Ministry of Economics and Climate Protection and currently brings together 101 research associations and 1,200 research institutions. One of these research areas, represented by the Research Association of German Toolmakers, Forschungsgemeinschaft Deutscher Werkzeug- und Formenbauer FDWF e.V., concerns the question of whether and how the advantages of additively manufactured tools can be measured in the extrusion process. And that brings us to Schmalkalden University of Applied Sciences.

The research project

The ExAM research project shifts the focus away from conventionally manufactured tools, which are produced subtractively, i.e. cutting machining process, towards the process of additive manufacturing. This is already established in other areas – both in general and in the field of plastics production – and now the question arises as to whether these advantages can be transferred to the extrusion process. One obvious benefit is that additive processes offer more degrees of freedom in the production of tools, thus enabling new and innovative approaches to design.

Traditionally, the tools are manufactured using machining processes such as milling, turning or electrical discharge machining. A necessary consequence of this procedure is restrictions such as transitions and dead spaces, which have a negative impact on the flow of the melt. The layer-by-layer structure of additive manufacturing can avoid precisely these restrictions. The optimization of the tools then leads to an improvement in the products and the manufacturing process: better component properties and more dimensionally accurate parts are just as much goals as the more robust and simpler design of the processes. Among other things, the optical properties can be optimized and part rejects minimized. In short, engineers have more options when it comes to design: However, the question of whether the additional expense of additive manufacturing is worth it remains unanswered.

Die

Let’s focus on the possibilities: The central point is the guidance of the melt in the mold, which should be guided as homogeneously as possible to the exit point and brought into shape. Stagnation, jams and dead spaces must also be avoided in terms of material quality, as these lead to streaks or color defects, among other things. The material that accumulates in dead spaces degrades over time, disrupts the flow and has negative effects on the mechanical and optical properties of the material. It is also important to control the speed of the melt, which in turn depends on the pressure and temperature. Additive manufacturing of the tools allows the implementation of targeted temperature control and therefore the best possible design of the melt channels and guidance. At the same time, innovative geometries in the form of cooling channels can be introduced into the tool.

The aim of the design is to optimize the melting chamber, allowing the fastest possible throughput while maintaining the same quality. The increase in efficiency can offer decisive advantages in mass production. This economic benefit in production, which additive components provide, is to be clarified in the ExAM research project. At the end of the project, in addition to evaluating the advantages, a guideline will be developed which will prepare the design and layout of additively manufactured components and be available to all cooperation partners. The companies can then use these guidelines to develop additive tools according to their own requirements and objectives. This basic accessibility means that the technology of additive manufacturing of tools can be widely applied, and the innovative impetus can be used to increase product quality features.

Innovative transfer

The use of additively manufactured and optimized tools is by no means new territory in the field of injection molding, but it is for the extrusion process. It is therefore less important to develop new technologies than to transfer existing ones to a new area. In this way, existing experience from injection molding can be used in aspects such as temperature and flow control of the melt. As a result of the fundamental application orientation, this topic lends itself as a cooperative project of industrial joint research (IGF), whereby all participating companies should be able to benefit from the technologies researched. As a project located here, the focus is on application proximity, i.e. the envisaged competitive advantages of the cooperating institutions and companies.

The two-year ExAM project started last fall and brings together three cooperation partners with three different spotlights: Schmalkalden University of Applied Sciences is focusing on extrusion and the field of health tech; Plastics Technology at Paderborn University is concentrating on the technical profile; and the Fraunhofer Institute for Additive Production Technologies, based in Hamburg-Bergedorf, is specializing in the project on the topic of simulation and additive manufacturing of tools using the laser-based powder bed process. 

The variety of shapes in the design made possible by the additive process is a challenge for HSM, as it opens up many new options. At the same time, however, this is also where the innovative optimization of the tools comes in. In addition to the actual shape of the component, various tool steels for the additive laser melting process are also being investigated, whereby the focus is always on types that are already commercially available. It is important that the subsequent use is uncomplicated. Last but not least, each individual optimization must take into account the entire process of the extrusion system and consider possible interactions.

Team presenting the 3D printer

The Faculty of Mechanical Engineering and its research group of applied plastics technology (Angewandte Kunststofftechnik AKT) recently announced a new acquisition that can also support research on the ExAM project: The innovative 3D printer from the manufacturer NewAIM3D was successfully put into operation and is now available for research and teaching. This printer, based on the pellet direct extruder principle, makes it possible to directly and efficiently process plastics and compounds in commercially available pellet form. For example, printing with pellets consisting of metal powder and binder, so-called feedstocks, is possible. The resulting components are then sintered to achieve the density and properties of conventional steels. The process thus represents an alternative to the established but costly additive laser melting process for metal powders. The acquisition of the printer was made possible as part of the third funding period of the Thuringian Center for Mechanical Engineering and was funded by the Thuringian Ministry of Economic Affairs, Agriculture and Rural Areas. The Free State of Thuringia also supports the project, which is co-financed by the European Union as part of the European Regional Development Fund (ERDF).