Process-Integrated Quality Control for Non-Markable Microcomponents Using Fingerprint Technology

• Applicant: Professorin Dr.-Ing. Gisela Lanza
• Subject Area: Production Systems, Operations Management, Quality Management and Factory Planning
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 558682077

The QMikF project (Process-Integrated Quality Control for Non-Markable Microcomponents Using Fingerprint Technology) aims to develop an innovative quality assurance methodology for microcomponent manufacturing. High-precision components, such as micro-gears in dental instruments, require strict tolerances below 10 μm. Current metrology technologies often detect deviations too late, leading to inefficient production processes and increased scrap rates. To address this, the project combines two technological approaches: Virtual Metrology (VM) and marker-free component tracking using fingerprint technology. VM enables model-based quality predictions based on process data, particularly through acoustic emission sensors. This allows real-time detection of deviations and immediate corrective actions within the production process. The fingerprint technology enables unique identification of each microcomponent without additional marking, ensuring secure traceability of quality data. This is crucial since traditional marking methods are not feasible due to the small part size, functional surfaces, and downstream processes. The project tackles two key challenges: first, developing a robust prediction pipeline that accounts for uncertainties and concept drift; second, industrializing fingerprint technology and integrating it into the production process. The validation use case focuses on micro-gears for dental instruments, which impose the highest demands on quality and process stability. The combination of VM and fingerprint technology is expected to revolutionize quality assurance, reduce scrap, and enhance competitiveness in microcomponent manufacturing.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Dentsply Sirona Deutschland GmbH; Kistler Straubenhardt GmbH
• Cooperation Partner: Professor Dr. Daniel Carl
• Co-Investigator: Professor Dr.-Ing. Florian Stamer