Kick-off for the R&D project “HyperFoil” – hyperspectral technology for film substrates

On December 10, 2025, the research and development project “HyperFoil – Hyperspectral Camera-Assisted Selective Laser Paint Removal from Backlit Film Carriers”, funded by the German Federal Ministry of Research, Technology and Space, was launched at Fraunhofer IFAM in Bremen. The project aims to leverage hyperspectral technology to meet increasing demands for structural precision, edge sharpness, and design freedom across a wide range of industries. SITEC contributes its extensive expertise in the automation of material-adapted laser ablation processes.

Rethinking precision: Objectives and technological core

The goal of the R&D project HyperFoil is to develop a robust and reproducible approach for generating ultra-fine surface structures on film substrates. Integrating a hyperspectral camera (HSI) into the automated laser process is key to achieving this. This enables the differentiation between coating systems and the reliable identification of local material and layer inhomogeneities.

SITEC is contributing its expertise in the real-time positioning of the laser beam. By synchronising the beam position with position-accurate spectral data from the HSI camera, the laser processing parameters can be dynamically and material-dependently adjusted during the process. This allows layer residues to be specifically detected after laser processing and reworked locally automatically. This ensures consistently high edge quality and increased process reliability.

From data streams to process control: project scope and implementation

The project investigates how hyperspectral technology can be efficiently integrated into industrial process chains. The resulting spectral data form the basis for adaptive process control and integrated quality assurance.

Following the definition of process and system requirements, SITEC supports the selection of suitable laser sources and scanners. Based on this, relevant laser parameters are systematically analyzed using DOE plans and evaluated with regard to their impact on the overall process. In parallel, Fraunhofer IFAM conducts comprehensive laser parameter studies and continuous characterization of the processed surfaces. SITEC is involved in evaluating the results and assessing potential feedback mechanisms for closed-loop process control.

Industrialization in focus: system integration and added values

A key focus of the project is the transferability of the developed approaches to large-scale industrial applications. The project partners jointly develop a holistic control and data-processing concept that integrates all subsystems and relevant interfaces.

SITEC is responsible for integrating all hardware and software components into a real-time-capable overall system. In cooperation with Fraunhofer IFAM, the hyperspectral imaging (HSI) datasets are processed and transformed into a global coordinate system serving as a reference for the entire process. The overall system is subsequently demonstrated at pilot-scale level to validate the interaction of all components under realistic application conditions.

The project HyperFoil addresses key challenges in industries such as automotive, household appliances, furniture, and electronics. Increased process reliability and reproducibility enable economically optimized implementation and clear exploitation paths: from direct use of the developed technologies in new systems to integration into existing products of SITEC. In addition, the planned integration of AI and machine learning methods provides further competitive advantages and contributes to strengthening Germany as an industrial and innovation hub.

Other project partners: HAIP Solutions GmbH, Mankiewicz Coating Solutions