As part of the FFG project QuaL-DED, a multi-partner consortium developed a robot-compatible laser spectroscopy system enabling real-time chemical analysis during additive metal deposition.

Using Laser-Induced Breakdown Spectroscopy (LIBS), the system provides direct, in-process monitoring of alloy composition — enabling full quality control in the production of functionally-graded materials (FGMs), also known as Nabla materials.

FGAM (Functionally-Graded Additive Manufacturing) makes it possible to spatially tailor material properties — such as hardness, oxidation resistance, or thermal behavior — within a single metal part. This is especially relevant for high-performance aerospace applications (e.g. turbine blades, nozzles, propulsion components) that require multiple material zones without joining, layering, or post-processing.

Impact:
The technology enables truly zero-waste, on-demand production of complex, high-value parts — with only the necessary alloy deployed, at exactly the required location and concentration.

This marks a fundamental shift in how we design and manufacture critical components: adaptive, integrated, and lean by technology — not by compromise.

In collaboration with a pioneering developer of ceramic-on-glass memory systems, we co-developed the femtosecond laser core architecture behind a high-density, non-volatile optical storage platform — designed for scalable, energy-efficient long-term archiving.

A coverage by Business Wire confirms the system’s relevance for hyperscale infrastructure and its potential to outperform conventional archival technologies in both lifetime and cost efficiency.

Over a four-year partnership — starting with a two-person engineering team — we:

• developed the core nanostructuring and beam delivery system,
• designed and commissioned the first industrial-grade prototype facility,
• engaged top-tier European experts in ultrashort-pulse lasers, micromachining, and precision optics,
• and leveraged our deep-tech experience to bring the technology from lab to pilot scale within two years.

Impact:
A sustainable storage solution, matched with industrial readiness and technical elegance, combining physical robustness, zero-energy retention, and process efficiency — ready to meet the future demands of data-driven industries.

Building on our research published in Applied Surface Science, we pioneered a closed-loop laser nanomachining system that moves beyond conventional template-based (CAD) approaches.

At its core lies a breakthrough in real-time z-axis focus control, enabling the laser to autonomously adapt to unknown or irregular surface topographies during processing. This transforms laser machining from a pre-scripted procedure into an intelligent, self-correcting operation.

Unlike traditional systems, which require perfectly characterized surfaces, our method dynamically maintains nanometer-precision focus — even when machining on curved, misaligned, or previously uncharted surfaces.

Applications span multiple domains:

• Autonomous microsurgery — precise, minimally invasive interventions on living tissue with real-time adaptive focus,
• Semiconductor repair & IC editing — sub-micron operations on sensitive chip architectures where CAD guidance falls short,
• Advanced manufacturing — high-value precision components machined without laborious pre-alignment or rework.

Impact:
This technology unlocks a new paradigm: laser systems that "see and decide" in-process, combining nanometer accuracy with autonomous adaptability. It marks a step towards the future of smart, AI-assisted laser manufacturing and biomedical interventions, where precision is no longer constrained by prior knowledge of the workpiece.