The latest episode of the Galvano-Talk podcast is dedicated to one of the most important future topics in surface technology: the digitalization of electroplating processes. Dr. Martin Metzner, Head of the Surfaces and Materials research department, and Klaus Schmid, Head of the Electroplating Processes and Systems research team, were invited as guests.
Learning electroplating as a digitalization platform
One focus of the discussion was on Fraunhofer IPA's so-called "learning electroplating" - a 60-litre electroplating system that serves as a research platform for digitalization projects. "We have installed everything we would like to see in terms of measurement technology in an electroplating plant," explains Schmid. Particularly innovative features such as split anode rails enable precise current measurements at four positions and thus uncover irregularities that remain hidden with conventional measurement technology.
Soft sensors: the next evolutionary step
A key topic was the development of soft sensor technologies. These make it possible to calculate electrolyte concentrations in real time by intelligently linking production data, laboratory values and system data. "This is a huge step forward," emphasizes Schmid. "You can get things online where you might have waited two weeks for an analysis."
DigiChrom: AI meets complex electrochemistry
The BMBF-funded DigiChrom project is an example of how artificial intelligence can be used in electroplating technology. The interdisciplinary consortium is working on making the complex chromium III processes more manageable through digitalization. "We want to move away from trial and error in materials science," explains Metzner.
Focus on practical relevance
Both experts emphasized the close links between research and industrial application. Current projects range from the coating of carbon tubes for the aviation industry to the development of completely new in-house electroplating systems for machine manufacturers. "We are closing the gap between outstanding basic research and industrial application," says Metzner.
Young talent crisis as a key challenge
Alarming figures shaped the discussion about the shortage of skilled workers: the number of graduates in surface technology has fallen from 288 (2010) to just 83 (2024). "That's not even a third," warns Schmid and sees this as one of the biggest challenges facing the industry.
Outlook: Automation yes, but with a sense of proportion
Both experts were optimistic but realistic about the future of electroplating technology. While automation and AI are important tools, they emphasize the indispensable role of humans: "Even then, I still need someone to monitor the whole thing," says Schmid.
