HoKiTEP – Highly Kinematised Technology Development Platform

Background & Motivation

The trend toward highly individualized components is a central challenge for modern industrial production – particularly in aerospace. Increasing individualization leads to ever-smaller batch sizes and makes classical automation paradigms designed for mass production increasingly uneconomical.

In addition, technological change – driven by environmental regulations, market shifts, and scientific progress – as well as disruptive technologies such as Artificial Intelligence (AI), continue to push forward the requirements placed on production systems. Companies face the challenge of protecting their existing investments while remaining future-proof.

Flexibility is therefore the key competency of the next generation of production systems. The DLR-ZLP Augsburg does not understand flexibility merely as variant management, but as the ability to respond quickly and with low barriers to changing material, component, process, and market requirements – without rendering existing equipment obsolete.

Preliminary Work: The Multifunctional Cell (MFZ)

More than ten years ago, the DLR-ZLP Augsburg already recognized this challenge and, with the construction of the Multifunctional Cell (MFZ – Multifunktionale Zelle), developed a pioneering solution for flexible production technology in aerospace. The MFZ positioned the DLR-ZLP as a leading institute in the field of flexible manufacturing research.

Vision & Objectives

HoKiTEP (Highly Kinematized Technology Development Platform – Hoch-Kinematisierte Technologie-Entwicklungs-Plattform) is a research initiative within the AI Production Network Augsburg. The goal is to build and operate a state-of-the-art, future-ready research infrastructure for flexible and AI-supported production technology.

The HoKiTEP platform fundamentally expands the capability portfolio of the DLR-ZLP Augsburg and offers a unique environment for industry-relevant research and technology transfer.

Facility Concept & System Architecture

At the heart of the HoKiTEP platform is the interaction between mobile, flexible robotic units and two stationary robots mounted on linear axes. This combination makes it possible to represent a wide variety of production scenarios with strongly varying build spaces and levels of complexity.

The facility is complemented by an intelligent functional environment that integrates the following core capabilities:

• Communication and coordination between robots and mobile units
• Energy management and smart maintenance strategies
• AI-supported task planning and cell configuration
• Safe human-robot collaboration (HRC)
• Automated and adaptive cell configuration

Scientific Research Focus Areas

1. Flexible Robotics & Automation

In the field of flexible robotics and automation, methods for location-independent coordination of stationary and mobile robot units are being researched. The focus lies on AI-supported path planning, sensor-based environment perception, and safe collaboration between humans and machines in dynamic production environments.

2. Process Development & New Materials

Process research at HoKiTEP encompasses two central thematic areas:

• Bio-based materials: Investigation and qualification of sustainable, bio-based materials for use in the aviation industry with regard to their mechanical properties and processability.
• High-rate RTM process: Development of an industrially applicable Resin Transfer Moulding (RTM) process for aerospace applications, supported by extensive sensor technology and AI-based process control.

3. Precision Assembly & Tolerance Management

The modular design of the HoKiTEP facility provides optimal conditions for researching high-precision assembly processes for geometrically variable aerospace components.

Core topics include:

• Automated tolerance management and component matching
• In-situ shimming based on resistance welding processes
• Automated disassembly and maintenance of aviation structures

4. Quality Assurance & Digital Twin

At HoKiTEP, quality assurance is understood as an integral part of the production process. Active measurement technology and real-time production data are used to make continuous statements about component quality via digital twins and AI algorithms.

Research topics in this area include:

• Development and integration of production-accompanying sensor systems
• Data management and analysis for real-time quality forecasts
• Development and validation of digital twin models for manufacturing processes

Societal & Economic Significance

HoKiTEP makes a direct contribution to securing and strengthening the Augsburg-Swabia production location and to the future viability of the Bavarian aviation industry. The platform specifically builds a bridge between academic basic research and industrial application:

• Impulses for industry: Joint projects with companies to integrate modern production paradigms
• Closing gaps: Identifying and closing technological gaps in the field of flexible automation and AI-supported production
• Regional added value: Strengthening the AI Production Network Augsburg and Bavaria's innovative capacity
• Sustainability: Contributing to resource-efficient and bio-based manufacturing in aviation

Funding