Powerful premiere in Berlin: Fraunhofer IPK invests in WLAM with ProFocus

With the successful commissioning of a ProFocus LaserCell at the Fraunhofer Institute for Production Systems and Design Technology (Fraunhofer IPK), a brand-new technology is being launched in the institute’s renowned machine hall. This strategic investment in robot-guided laser metal deposition sends a strong signal to the metalworking industry, as ProFocus’s fully digital process chain, from scanner integration to the final robot program, offers entirely new technical and economic possibilities. The cherry on top? Maximum resource conservation through wire-based deposition, because, unlike the powder process, the entire material remains on the component.

A project of reference for Europe and beyond

Fraunhofer IPK has been researching and developing pioneering processes for the repair and reconditioning of industrial metal components for many years. With the ProFocus LaserCell, a system is now in operation that combines various competencies: scanner-based measurement of damaged areas, automated path planning, and highly stable laser processing with AI-based control and an intuitive HMI. This creates a seamless workflow – from the initial scan of the defective component to the finished, welded workpiece.

The particular strength of this system lies in the seamless integration of the scanner and path planning technologies developed by SKM DCAM. Since the component does not need to be re-clamped, manual planning steps can be minimized and repair strategies can be calculated automatically. This represents a significant advantage in overall efficiency and user-friendliness compared to other solutions currently available on the market.

Laser wire deposition – robust and versatile

A central element of the solution at the IPK is laser wire deposition. This technology is characterized by particularly clean process control and opens up new possibilities for processing materials that were previously considered difficult or impossible to repair. A prime example is cast iron, which was previously considered only partially weldable due to its brittle properties.

The ProFocus LaserCell enables the controlled build-up and repair of such materials. This reduces costs and replacement times for spare parts and significantly extends the service life of machine components – a crucial factor for industries such as mechanical and plant engineering, energy, and transportation technology.

Practical applications

The range of applications for the ProFocus LaserCell is extensive:

Turbine components: Gas and steam turbines are exposed to enormous thermal stress. Even the smallest cracks can reduce efficiency or lead to failure. Laser-based wire deposition allows these damaged areas to be precisely repaired, allowing components to remain in service longer.

Casings and impellers: In chemical and power plants, cavitation and wear often lead to chipping of casings or impellers. Scanner-based repair enables precise repair without having to replace the entire component.

Tools in mechanical engineering: Molds, dies, and various special components are expensive to manufacture and often have complex geometries. Instead of being replaced after a defect, they can now be welded on and reused – with minimal material usage and maximum precision.

Ship and offshore components: Propellers, shaft bearings, or pumps can be precisely repaired despite corrosion and cavitation. This reduces downtime and increases operational capability in maritime operations.

Consistent digitalization as the key

The digitalization of the process chain is more than just a technical detail: In practice, it means maximum transparency, efficiency, and simplified work for the operator. Every processing step is documented, verified, and traceable.

For users, this means:

• High process reliability through automated planning and execution
• Short lead times thanks to direct integration of scanning, planning, and the welding process
• Reproducibility even with complex components or changing batches

The system at Fraunhofer IPK thus establishes a model for what repair and remanufacturing processes could look like in the future – standardized, digitalized, and sustainable.

Profitable and Sustainable Welding

Resource-efficient metal component repair is becoming increasingly important in light of rising raw material prices and growing environmental demands. Wire laser cladding is a key technology in this area: Instead of scrapping defective components, they can be reprocessed and reused. This not only saves costs and time but also avoids unnecessary CO₂ emissions from energy-intensive new production. Recent history has also shown that reduced dependence on global supply chains is a decisive strategic advantage.

The successful commissioning of the ProFocus LaserCell at Fraunhofer IPK demonstrates how practically applied research can respond to industrial requirements – and how closely sustainability and competitiveness are linked.

A showcase for the metalworking industry

The historic machine hall at Fraunhofer IPK is not only a research environment, but also a showcase for industry. Companies from the fields of mechanical engineering, energy supply, transportation technology, and aerospace now have the opportunity to experience the performance of the new LaserCell under realistic conditions.

Interested companies can expect a well-thought-out, comprehensive process: from the initial digital scan through automated path planning to precise welding – live and reproducible. This allows them to experience how the repair of complex metal components is fundamentally changing through the combination of digital planning and robust wire deposition welding.

Conclusion: laser wire deposition is key to industrial repair welding

The commissioning of the ProFocus LaserCell at Fraunhofer IPK is a visible sign of how digital process chains, modern welding technologies, and sustainable strategies intertwine. For the industry, this offers a practical reference project that will have a lasting impact on the future of industrial wire deposition welding.

👉 Seize the opportunity to take your repair and manufacturing processes to the next level. With the ProFocus LaserCell and OSCAR-PLT technologies, you can increase efficiency, precision, and sustainability.

👉 Contact us now and secure your lead in the metal processing industry.

Stop replacing cast iron parts and start 3D repairs with coaxial laser processing

Why focus on cast iron repair?

Cast iron continues to play a vital role in components such as machine parts, gearbox housings and hydraulic units – across industries from agriculture and mining to utilities, construction, transport, retail and hospitality. Its high stiffness, corrosion resistance and damping capacity make it a cost-effective material.

But when it comes to maintenance, cast iron quickly becomes a challenge:

• high susceptibility to cracking
• difficult heat input control
• often no cost-effective alternative to new production

This is exactly where OSCAR-PLT’s laser-based repair approach comes into play.

From 26 to 28 August 2025, OSCAR-PLT will attend the Nordic Laser Material Processing Conference (NOLAMP) for the first time. The event is one of Europe’s most important gatherings for laser-based manufacturing and repair technologies.

With a practice-driven talk on the additive repair of cast iron components, OSCAR-PLT will present its ProFocus technology – and a highly relevant solution for many industrial maintenance challenges.

Talk: Additive repair of cast iron materials using coaxial laser wire cladding

The focus of the NOLAMP presentation is the application of OSCAR-PLT’s ProFocus technology for precise and resource-efficient repair of cast iron components – without the need for preheating.

The presentation highlights:

• selection of suitable filler materials (e.g. NiTi4, quEISI®)
• development of stable process parameters (laser power, wire feed)
• two real-world case studies from industrial maintenance

It’s time to shift from replacement to repair. Our studies show that a wide range of materials – including GJS and GJL grades – can be reliably repaired using our ProFocus technology: crack-free and without time-consuming preheating.

— Ulf Jasnau, customer project lead & sales engineer at OSCAR-PLT

---

The technology behind it: ProFocus

The patented ProFocus optic was developed specifically for coaxial wire-based cladding and has proven itself in industrial use since 2019. Its ring-shaped laser beam delivery enables direct energy input into the filler metal, drastically reducing the heat-affected zone on the base material.

Key technical advantages at a glance:

• No preheating or postheating required
• Fully automated, robot-guided welding process
• 100% wire utilisation, no powder loss
• Free choice of wire materials
• High precision

---

Case study 1: Repairing a cast iron housing

The gearbox housing, made of EN-GJS-400-18-8-LT, showed deep cracks along the flange surface. The repair was completed in four steps:

1. Milling out the damaged area (up to 10 mm depth)
2. Cladding with NiTi4 wire – no preheating, directly on base material
3. Layered build-up with 12 layers, total of 2.3 kg wire
4. Non-destructive testing (PT): no cracks, no delamination

The full repair was carried out under near-industrial conditions on a full-size component. The result: full compliance with dimensional and surface quality requirements.

---

Case study 2: Hardfacing of a hydraulic component

A second case involved the hardfacing of a heavily used hydraulic shaft made of EN-GJS-600-3. The issue: damaged chrome coating around the sealing surface; target hardness: approx. 65 HRC.

Approach:

• Specially developed wire by quada V+F® (C 1%, Cr 4%, Mo 8%, V 2%)
• Cladding in spiral path using ProFocus to avoid stop-start transitions
• Result: hardness up to 930 HV0.1, no cracking, excellent bonding

The deposited layer was then ground to final dimensions and successfully PT-tested.

---

Benefits for industrial users

Additive repair of cast iron using ProFocus technology enables:

• Cost savings through reuse of high-value components
• Time savings through elimination of spare part lead times
• Material savings through precise layer build-up
• CO₂ reduction by extending part lifecycles and reducing new production
• Higher asset availability through rapid on-site maintenance

---

Looking ahead: additive repair as part of modern maintenance

The techniques presented offer industrial users a field-proven solution for restoring damaged cast iron components in a reliable and sustainable manner. ProFocus wire-based cladding is particularly suitable for applications where high quality standards meet tight maintenance windows.

OSCAR-PLT continues to develop its approach, with a focus on:

• Combining additive processes with milling for automated surface prep
• Expanding wire materials, e.g. cored wires
• 3D repair strategies for complex geometries

---

Conclusion: cast iron repair pays off

Participating in NOLAMP 2025 is an excellent opportunity for OSCAR-PLT to present its proven solution for additive repair of metallic components to the Scandinavian market. With technology expertise, real-world experience and robust implementation, we support our customers as long-term partners in the future of industrial maintenance.

Want to know more? Get in touch!

New milestone: Digital process chain for 3D metal printing and additive repairs

OSCAR-PLT, together with S.K.M. Informatik, is setting new standards for additive manufacturing and repair. The integration of SKM DCAM’s scanner and path planning technologies into proven ProFocus laser systems enables, for the first time, complete integration of scanners, path planning and robot programming for laser metal deposition.

This groundbreaking development significantly increases efficiency and user-friendliness in 3D metal manufacturing and repair. A particular advantage: ProFocus laser heads produce with both wire and powder, thus offering maritime companies unique flexibility for a wide range of applications in the areas of repair, retrofitting, and remanufacturing.

“The trend toward 3D repair and remanufacturing of high-quality metal parts is increasing, including in the maritime industry. ProFocus laser technology provides a reliable solution to free yourself from dependence on international supply chains and costly spare parts inventories,” explains Dr.-Ing. Michael Schnick, Managing Director of OSCAR-PLT.

OSCAR-PLT and S.K.M. will present this innovative technology integration at the Schweissen und Schneiden trade fair from September 15 to 19, 2025, in Essen. If you don’t want to wait that long, you can find out more and contact us directly.

Discover today how laser metal deposition with the ProFocus LaserCell can take your production, maintenance, and repair processes to a new level: economical, reliable and sustainable.

OSCAR-PLT: Your One-Stop Shop for customised repair solutions in additive metal manufacturing

What if repairing your high-value metal components were not only feasible and sustainable but also economically attractive? Especially when dealing with expensive or heavily stressed components, numerous questions arise: Is the repair viable? What quality can be expected from the repaired part? What are the costs?

This is precisely where OSCAR-PLT steps in, offering comprehensive solutions—all from a single source. As an experienced provider of metal 3D printing systems for laser-based deposition welding, OSCAR-PLT supports customers not only with high-quality equipment but also extensive expertise and personalised consultancy as a true one-stop shop.

Why OSCAR-PLT? Key benefits at a glance

Comprehensive consulting and feasibility studies: In our in-house application centre, we assess whether and how your specific requirements can be optimally met. Here, concrete solutions are tested and optimised.

Material flexibility: ProFocus technology offers exceptional flexibility in material selection due to its rapid switching between wire and powder processes (under 10 seconds) and a wide range of available materials. Combining materials can even enhance component performance.

Quality and precision: Thanks to advanced scanning technology and precise motion systems, OSCAR-PLT leads in accuracy and quality of produced parts.

Customised system solutions: Whether the proven ProFocus LaserCell or individually designed special machines for mobile use, OSCAR-PLT provides systems perfectly tailored to your needs.

Premium training: Customers naturally receive comprehensive training to ensure safe and effective operation of the equipment.

Sustainability and cost-efficiency: Repairs can be performed at a fraction of the cost of new components, significantly saving resources and reducing CO₂ emissions.

What does this look like in practice?

Imagine a customer in the mining industry struggling with significant wear on the slugs of their roller crushers. Each new component costs around €50,000 and must be stored in inventory to avoid costly downtimes. Instead of expensive new purchases, possibly delayed by supply chain bottlenecks (especially in the event of another pandemic or geopolitical disruptions), the customer approaches OSCAR-PLT. Our experts analyse the issue, evaluate feasibility, and collaboratively select suitable materials and methods.

This is followed by a feasibility project, where the component is repaired using laser-based deposition welding and possibly improved in its properties. The customer pays only for the actual repair effort—a fraction of the new component cost. For instance, the crusher roller can be repaired for about €8,000 and then tested under real conditions.

If the repair proves economically viable long-term, OSCAR-PLT continues to support the customer, either supplying a tailored system including comprehensive training or establishing contacts with specialised contract manufacturers. Additionally, customers can leverage their ProFocus equipment profitably for external services, opening up new business opportunities and positively impacting their financial outcomes.

Overview of our services

• Detailed analysis and individual consulting
• Conducting feasibility studies in our in-house application centre
• Development of tailored solutions
• Design and implementation of customised systems, including operator training
• Our goal: Long-term partnerships and reliable support

OSCAR-PLT stands for quality, competence, and customer-oriented solutions—from initial consultation to turnkey systems. Rely on our extensive expertise and benefit from efficient, sustainable, and cost-effective production.

Would you like to learn more? Request information here.

Do you have specific questions?

Together, our sales engineers Dr Tobias Gustmann and Ulf Jasnau bring over 40 years of experience to the conversation. Let them know about your technical requirements and they will advise you on the best technology for your specific use case. Should it become clear during the consultation that your application isn’t suited for OSCAR-PLT’s laser welding systems, Tobias and Ulf will gladly provide objective recommendations for alternatives.

2024 in review

2024 was a decisive year for additive manufacturing and also for OSCAR-PLT. The advance of DED technologies was noticeable everywhere, not least at this year’s Formnext, where the growing demand for high-quality DED solutions was clearly noticeable. Even in economically uncertain times, there is a global need for high-performance future technologies that impress with their reliable quality and uncomplicated handling.

We have celebrated many highlights over the past twelve months, and here we present our top 5 of the year – with a big thank you to all our customers, partners and team members. Together we make the impossible possible!

1. System of the year: ProFocus LaserCell

The ProFocus LaserCell is our future-proof all-in-one solution for production, repair and coating. With a 6-axis robot and state-of-the-art process control, this system is designed for maximum flexibility and precision. Intuitive operation and functions such as Path Planning, StartControl and the WireWatcher ensure maximum process stability and efficiency. Whether small components or large workpieces – the LaserCell masters every challenge.

2. Application study of the year: Wear protection for hydraulic components

A real milestone: Together with our partner Metrom, we have coated a hydraulic component made of GJS-600 for use in open-cast mining vehicles. This application offers a crack-free coating hardness of 65 HRC and replaces environmentally harmful hard chrome plating. The component is currently being tested in open-cast mining and is showing impressive results in terms of durability and wear protection. This solution proves how sustainable technologies can replace traditional methods.

3. Software development of the year: Scanner integration

Our cooperation with S.K.M. Informatik has taken our systems to a new level. With scanner integration, component geometries can be captured directly in the coordinate system of the laser cell and compared with target geometries. This technology enables precise path planning, particularly in 3D repair applications where worn components no longer provide complete data. The advantages? Time savings, precise results and even more efficient repairs.

4. 3D repair of the year: 1970 seal housing

We repaired a water-cooled seal housing for a hydraulic cylinder in a blast furnace for Hansa-Flex – a component that has not been produced since 1970.The repair required a precise choice of material in order to fulfil the different thermal expansion coefficients. The inner housing was coated with a copper-based alloy, while the outer surfaces were reworked from mild steel. This measure impressively demonstrates how additive repair processes can extend the service life of components.

5. Hardware development of the year: ProFocus LaserCell Compact

The ProFocus LaserCell Compact is currently under development and will provide the ideal solution for feasibility studies and the production of small components. With an ultra-light laser head weighing just 6 kg, the system is exceptionally flexible and precise. Even difficult materials such as aluminium or copper alloys can be processed with ease. In particular, the reliability and user-friendliness of this space-saving system will help customers to make their production faster and more cost-efficient.

Looking ahead to 2025: With these successes behind us, we look forward to working with you on the challenges of manufacturing in the coming year.

Technical challenges are what drive us – and we are ready to continue shaping the future of the industry!