Research Projects with Optris

01. IDEEL: Implementation of Laser Drying Processes

The IDEEL project investigates laser drying as an energy-efficient alternative for lithium-ion battery production. Inline temperature monitoring supports precise process control, reduces material waste, and enables the technology to be scaled from laboratory to industrial production. The approach could lower energy use, space requirements, CO₂ emissions, and manufacturing costs.

01. IDEEL: Implementation of Laser Drying Processes

01. Steam Boiler Furnace Gas Temperature

This study determines the emissivity and temperature of combustion gases during peat firing in a steam boiler. Optris CTlaser F2 and F6 pyrometers, combined with the TEMPER software, enable accurate temperature measurements at different furnace heights. The method supports combustion monitoring to reduce slagging and nitrogen oxide emissions.

01. Steam Boiler Furnace Gas Temperature

02. Direct Biogas Reforming

This study explores microwave-assisted biogas reforming as a potential negative-emission process. An Optris CTratio 2M pyrometer and PI 1M infrared camera ensure precise, homogeneous temperature control. The process achieves conversion rates comparable to conventional heating without prior gas separation or recycling.

02. Direct Biogas Reforming

02. OsTOS: Oven System for Tailored Organo Sheets

The OSTOS project develops textile-based sensor systems for monitoring strain and deformation in lightweight structures. Flexible sensor networks are integrated into composite materials to detect stress points continuously and without invasive inspection. The technology supports predictive maintenance, improved structural safety, and lower lifecycle costs in aerospace, automotive, and civil engineering.

02. OsTOS: Oven System for Tailored Organo Sheets

03. Polyline: Integrated Line Application of Polymer

The PolyLine project develops a flexible and fully automated system for integrated industrial production. Cyber-physical systems, robotics, automated guided vehicles, and data-driven control enable efficient coordination across diverse manufacturing processes. The approach improves scalability, reduces waste and operating costs, and supports sustainable, future-ready production.

03. Polyline: Integrated Line Application of Polymer

03. RGB and Thermal Imaging for Agricultural Robots

This study develops a dual-camera system for detecting water stress in lettuce plants using an agricultural robot. An Intel RealSense RGBD camera captures plant structure, while an Optris Xi 400 thermal camera measures surface temperature variations. Combined with YOLOv8, the system enables reliable real-time assessment of plant water stress for precision agriculture.

03. RGB and Thermal Imaging for Agricultural Robots

04. AutoPV: Autonomous Mobile Measuring

The AutoPV project develops an autonomous robot for inspecting and maintaining ground-mounted photovoltaic systems. Using navigation sensors, cameras, and a 3D laser scanner, the robot moves independently through the solar farm. An infrared camera detects faulty modules, while integrated scythes remove vegetation beneath the panels.

04. AutoPV: Autonomous Mobile Measuring

04. Quality Control of Liquid Aluminium Alloy

This study examines infrared thermography as a fast, non-contact method for assessing the quality of liquid aluminium alloys. An Optris PI thermal imaging camera monitors temperature changes during solidification and reveals a correlation between thermographic data and metal density. The results support the development of an automated inspection method for foundry production.

04. Quality Control of Liquid Aluminium Alloy

05. InSensa: Adaptive Process Control in Metal 3D Printing

The InSensa project develops advanced sensor and control systems for detecting and preventing errors in laser-based additive manufacturing. High-speed pyrometry, thermography, OCT, and 3D imaging enable multimodal process monitoring. Real-time laser power control responds within 50 µs and improves surface roughness by 20%, supporting future automatic defect detection.

05. InSensa: Adaptive Process Control in Metal 3D Printing

05. Urban Tree Temperatures During Extreme Heat

This study examines how urban trees reduce surface temperatures during the record-breaking 2022 heatwave in Forchheim, Germany. An Optris PI 450 thermal camera and a multispectral camera measured more than 3,000 trees across over 30 species. The results reveal species-specific cooling effects and provide valuable insights for climate-resilient urban planning.

05. Urban Tree Temperatures During Extreme Heat

06. HP3D: Large-Volume Components from Random Plasticss

The HP3D project develops a highly productive system for additive manufacturing of large thermoplastic components. Industrial robots, modular extruders, temperature control, laser post-processing, and process monitoring enable parts larger than one meter to be produced from standard plastic granules. The system also supports multi-material designs and integrated functional elements.

06. HP3D: Large-Volume Components from Random Plasticss

06. Strengthening SiC Ceramic Structures

This study improves the strength and thermal performance of 3D-printed silicon carbide ceramic structures. Direct ink writing is combined with precursor infiltration and high-temperature pyrolysis to reduce porosity and improve material density. The resulting SiC composites achieve up to 600% higher mechanical strength and improved heat dissipation for high-temperature applications.

06. Strengthening SiC Ceramic Structures

07. Cooling Effects on Al-Si Coated Steel

This study examines how cooling rate influences the microstructure and properties of Al-Si coated hot-press-forming steel. Rapid quenching limits elemental diffusion, reduces Kirkendall void formation, and decreases the thickness of the α-Fe(Al) layer. As a result, the quenched coating achieves higher hardness and improved mechanical properties.

07. Cooling Effects on Al-Si Coated Steel

07. SmartScan: Thermal Simulation of Laser Scanner Optics

The SmartScan project develops simulation methods for predicting temperature distribution and deformation in laser scanner optics. An equivalent heat source model, validated through irradiation and thermal measurements by Optris and project partners, accurately represents laser-induced heating. The results support focus-shift evaluation and more efficient design of complex multi-lens systems.

07. SmartScan: Thermal Simulation of Laser Scanner Optics

08. DIRTH: Mobile Thermal Imaging for Surgery

The DIRTH project develops a portable infrared thermography system for use in operating rooms. The compact device enables contactless monitoring of temperature and tissue blood flow with high spatial and thermal resolution. Advanced software supports static and dynamic image analysis, improving usability for surgical applications such as plastic surgery.

08. DIRTH: Mobile Thermal Imaging for Surgery

08. Temperature Measurement in Laser Heating

This study investigates temperature measurement during laser-based heating of machined optical components. Different measurement methods were used to analyze the thermal response of glass surfaces heated by an infrared laser. The results reveal a clear relationship between surface roughness and laser absorption, supporting improved control of optical manufacturing processes.

08. Temperature Measurement in Laser Heating

09. MicroUAV: Sensor System for Biodiversity Detection

The MicroUAV project develops a lightweight, modular sensor system for biodiversity monitoring with unmanned aerial vehicles. SWIR, VIS, NIR, and thermal sensors are combined to measure vegetation moisture and other environmental parameters. The system supports applications in precision agriculture, forestry, floodplain monitoring, and plant disease detection.

09. MicroUAV: Sensor System for Biodiversity Detection

09. Thermal Monitoring for Assistive Robots

This study presents a contactless physiological monitoring system for assistive robots using thermal imaging. Facial temperature changes are analyzed to estimate respiration and heart rate without physical sensors. Integrated into a home-assistance robot, the system supports non-invasive health monitoring for elderly people.

09. Thermal Monitoring for Assistive Robots

10. ICU Monitoring with Thermal Imaging

This study presents a contactless system for monitoring skin temperature and respiratory rate in intensive care patients using thermal imaging. Deep learning identifies relevant head and chest regions, while motion analysis extracts respiration-related chest movements. The system achieves real-time performance on low-cost embedded hardware, supporting continuous clinical monitoring without physical sensors.

10. ICU Monitoring with Thermal Imaging

10. Laser Welding Process on CrNi Steel Shells

This project investigates laser welding of ultra-thin CrNi steel shells for thermally resilient vacuum insulation panels. High-speed thermography is used to analyze micro-weld seams in 50 µm stainless steel cladding. The new design aims to withstand temperatures above 80 °C and expand the use of vacuum insulation in demanding applications.

10. Laser Welding Process on CrNi Steel Shells

11. Real-Time Testing of Laser-Welded Busbars

This study presents a real-time method for evaluating laser-welded aluminium busbar joints under electrical and mechanical loading. Resistance, temperature, and joint strength are measured simultaneously during lap-shear and torsion tests. The results reveal significant increases in resistance and temperature as the weld approaches failure, enabling a more realistic assessment of battery connection performance.

11. Real-Time Testing of Laser-Welded Busbars

12. Recycled Silicon Sludge for Semiconductor Packaging

This study recycles silicon sludge from semiconductor packaging to produce a silica-coated filler for epoxy molding compounds. An infrared camera was used to evaluate heat dissipation, showing improved thermal performance compared with conventional silica-based compounds. The results demonstrate a promising reuse of semiconductor waste in advanced packaging materials.

12. Recycled Silicon Sludge for Semiconductor Packaging

13. Safe Drying of Black Soldier Fly Larvae

This study evaluates microwave and radio-frequency drying for improving the microbiological quality and stability of black soldier fly larvae. Dielectric drying effectively reduces water activity and microbial contamination while maintaining product safety. The treated larvae remained microbiologically stable for six months, demonstrating an efficient alternative to oven and freeze drying.

13. Safe Drying of Black Soldier Fly Larvae

14. Radiation Resistance in AlGaN/GaN Transistors

This study examines how localized mechanical stresses influence the radiation resistance of AlGaN/GaN high electron mobility transistors. An electron wind force treatment reduces residual stresses and defects near electrically sensitive regions. Treated devices show lower degradation after irradiation, demonstrating a promising approach to improving transistor reliability in radiation-intensive environments.

14. Radiation Resistance in AlGaN/GaN Transistors

15. Microwave Methane Pyrolysis for Hydrogen

This study investigates microwave-assisted methane pyrolysis for producing hydrogen without direct carbon dioxide emissions. A fluidized bed reactor converts methane into hydrogen while capturing most of the resulting carbon in solid form. Compared with conventional heating, microwave heating increases methane conversion, carbon capture efficiency, and graphitic carbon production.

15. Microwave Methane Pyrolysis for Hydrogen

16. Fast Self-Repeating LCE Actuator

This study presents a fast, self-repeatable actuator based on a confined liquid crystal elastomer film. A rigid layer induces rapid temperature-controlled snapping motions in under 30 milliseconds without external assistance. The actuator demonstrates potential for applications including fire alarms and self-propelled soft robots.

16. Fast Self-Repeating LCE Actuator

17. Induction Heating of Metallic Biomaterials

This study evaluates non-contact induction heating of metallic biomaterials for potential use in treating implant-associated infections. Experiments and an analytical model examine how magnetic field strength and frequency influence material heating. A coated hip implant concept showed increased localized heating, supporting further development of magnetic hyperthermia treatments.

17. Induction Heating of Metallic Biomaterials

18. Thermal Haptic Feedback for Virtual Reality

This study presents an encountered-type haptic display that adds thermal feedback to virtual reality experiences. The system enables users to feel temperature changes without wearing additional devices. User testing shows that thermal feedback improves immersion and enriches the overall haptic experience in virtual environments.

18. Thermal Haptic Feedback for Virtual Reality