HYBDED | Hybrid manufacturing of mechatronic components

Mechatronic components in cold gas sprayed components

The aim of the HYBDED project is to implement mechatronic components in a cold gas sprayed component. For example, thermocouples can be used for temperature monitoring close to the active point in the component. By implementing RFID tags, cold gas sprayed high-performance components can be uniquely identified and protected against counterfeiting. For this purpose, a conventional cold gas cell is extended by another multi-axis robot with manipulator.


Bavarian Ministry of Economic Affairs, Regional Development and Energy
© StMWi

Implementation of mechatronic components in an additively manufactured high-performance component

The video shows the cold gas spray cell of Fraunhofer IGCV, which was extended by an additional multi-axis robot. During the interruption of the cold gas spraying process, the robot with the HYBDED front end removes a temperature sensor from the component magazine and places it on the build plate.

Integrated temperature sensors for data acquisition in high-performance components

Compared to powder bed-based processes (e.g., laser beam melting), Directed Energy Deposition (DED) processes are characterized by higher deposition rates and larger feasible component dimensions. Representatives of these processes are, for example, Wire Arc Additive Manufacturing (WAAM) or Cold Spray Additive Manufacturing (CSAM).

For companies, especially in the automotive, aerospace, and medical industries, additive manufacturing promises a wide range of new applications, and spare parts, in particular, can be reproduced quickly and easily.

With the integration of sensors into components, data can be collected at positions that were previously inaccessible or very difficult to access. Research is currently being conducted at Fraunhofer IGCV  to integrate PT100 temperature sensors into cold gas sprayed components. In addition to the optimal connection of the sensors, the focus is on the subsequent automation of the integration process (see video).

HYBDED: Additive production using cold gas spraying

Industrial robot with HYBDED front end
© Fraunhofer IGCV
Figure 1: Industrial robot with HYBDED front end

The HYBDED sub-project focuses on additive manufacturing using cold gas spraying, enabling a high order rate and thus short production times. The research project aims to insert sensors, and other mechatronic components into cold gas sprayed components in an automated and process-safe manner. To this end, the cold gas cell from the sister project FASTMULT is being expanded to include an additional industrial robot. This can be used to insert mechatronic components into the parts and overmold them. In addition to the gripper and monitoring technology, the module also has a milling spindle for preparing the required cavities to insert the components into the component in a process-safe manner.

One hurdle in the in-process integration of mechatronic components in cold spraying is the great mechanical stress on the components caused by the spray jet. For the successful integration of the components, they need to be prepared. For this purpose, a process concept (see figure 3) was developed, currently being qualified at Fraunhofer IGCV.

HYBDED front end (assembly mechanism at the front after the last robot joint)
© Fraunhofer IGCV
Figure 2: HYBDED front end (assembly mechanism at the front after the last robot joint)
Sequence concept for sensor integration using clips
© Fraunhofer IGCV
Figure 3: Sequence concept for sensor integration using clips

Cooperation with Fraunhofer IGCV

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Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles


We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.