Fraunhofer IPT: 3D thin glass by laser instead of etching

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How to Prevent Structural Distortions

This research work also involved the practical production of various sample components—including functionalized center consoles and windscreens, as we learn. However, because pre-structured glass blanks were formed in this way for the first time, the optimum process temperature had to be determined—a challenge! It had to be high enough for precise forming, but must not distort the microstructures. The IPT researchers therefore used various sensors, such as temperature sensors, to monitor the process. However, the forming process inevitably changes the previously introduced microstructures. To ensure that the structures still have the desired shape and position, a compensation method has been developed in Aachen that uses computer simulations to calculate the expected distortions in advance. These distortions are then taken into account during the structuring of the glass blank so that the correctly shaped structures are in the right place after forming. In plastics technology, this is known from pre-decorated blanks for cups, which only show the correct patterns and logos after thermoforming.

Laser Plus Non-Isothermal Forming is Best

And as part of a life cycle assessment (LCA), the process chains were also analyzed using key ecological criteria such as energy and material requirements. The combination of laser scribing and non-isothermal forming turned out to be very efficient in terms of CO₂ emissions, as the researchers report. And because both processes—laser structuring and non-isothermal forming—are completely electrical, the respective CO₂ emissions depend directly on the electricity mix used and will continue to fall as decarbonization progresses, they conclude

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Date: 08.12.2025

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