Simulation & digital services

Plasma simulation of a sputtering process with double tube targets (left), extraction of the erosion profiles on the targets (middle) and simulation of the coating current density on the substrate (right).
© Fraunhofer IST
Plasma simulation of a sputtering process with double tube targets (left), extraction of the erosion profiles on the targets (middle) and simulation of the coating current density on the substrate (right).

In combination with improved sensor-data acquisition, process simulation enables the exploitation of increasingly efficient and precise coating processes. As a result, the progressively increasing cost and quality requirements in thin-film technology can be fulfilled and additional information on the productivity and sustainability of process chains can be obtained.

At the Fraunhofer IST, we develop simulation software and codes in order to gain insights into the process dynamics and parameter-property relationships of coatings. Test series in process and plant development can thereby be partially substituted, enabling our customers to save time and costs. When carrying out simulation studies, we benefit from our expertise in thin-film coating technology. In addition, our extensive plant equipment enables the validation of our models. Furthermore, we are also offering know-how transfer via courses, hands-on training workshops and licensing of our simulation software.

Outlook – This is what awaits you!

Our physics-based simulation codes enable a multiscale overview from the process through to the coating and product properties. With the transfer of these codes into semi-empirical models and data-driven AI approaches, we are currently working on the development of real-time-capable digital twins of coating processes. In the future, this will allow the optimization and model-based monitoring of coating processes – with minimal time expenditure. Process drifts are tracked online by the model and the prediction of required maintenance avoids unnecessary rejects and increases the overall productivity of process chains.

Our expertise and fields of application in the area of Simulation & digital services

We offer optimization of low-pressure deposition processes, plasma and gasflow simulation, modelling of dust and aerosol transport, thermodynamic simulation as well as data acquisition and data science. The coating technology available at Fraunhofer IST allows for experimental validation. We offer software licenses (DSMC and PIC-MC method), support for HPC- and cloud computing, do simulation case studies and perform courses and training workshops.

 

Kinetic plasma and transport simulation for low-pressure processes

 

Simulation of the transport of dust and aerosols

 

Thermodynamic simulation based on the CALPHAD method

 

Flow simulation by computational fluid dynamics (CFD)

 

Data acquisition and model based process optimization

”Simulation enables the testing and evaluation of new processes prior to construction. Data collection and in-situ modeling form the foundation for knowledge-based process control for higher product quality and reduced waste.”

Dr. Andreas Pflug, Group Manager

We offer solutions for your applications

 

Industry solutions

Digital economy