New paths in tool production: EHLA technology from the Fraunhofer Institute

Wear protection Say Goodbye to Endless Milling: Forming Tools Reinvented

2025-01-03 A guest contribution by Martin Grolms | Translated by AI 6 min Reading Time

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The Fraunhofer Institute for Laser Technology ILT is breaking new ground: instead of milling forming tools from solid material, it applies wear-resistant functional layers near the final contour on affordable structural steel using extreme high-speed laser cladding (EHLA).

Demonstrator for EHLA technology: 3D printing and finishing through conventional milling characterize this tool, which allows bipolar plates to be manufactured economically, quickly, and sustainably in seconds in the future.(Image: Fraunhofer ILT) — Demonstrator for EHLA technology: 3D printing and finishing through conventional milling characterize this tool, which allows bipolar plates to be manufactured economically, quickly, and sustainably in seconds in the future.
(Image: Fraunhofer ILT)

The mass production of bipolar plates for fuel cells takes place every second. To protect the forming tools used from wear, they are milled from high-quality metal alloys. In the National Action Plan Fuel Cell Production (H2GO), the Fraunhofer Institute for Laser Technology ILT in Aachen (Germany) is taking new approaches: Instead of milling the tools from solid material, it applies wear-resistant functional layers close to the final contour on inexpensive construction steel using extreme high-speed laser material deposition (EHLA). The costs, construction time and wear of the tools are significantly reduced. Additionally, the EHLA process can be used for repairing damaged and worn tools—thus making a significant contribution to the circular economy.

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