With the inauguration of the new SCALE research building on the Mechanical Engineering Campus in Garbsen near Hanover in Germany on March 4, 2025, a major milestone in production technology has been achieved. Leibniz University Hannover, in collaboration with the state of Lower Saxony and the German federal government, invested approximately €50 million in this state-of-the-art research facility. A key component of the platform is the laser robot cell for 3D laser metal deposition, supplied by Nagel Technologies GmbH.
Automated Manufacturing for Complex Large Components
Nagel Technologies is providing an innovative solution for the production of large-scale components with its laser robot cell. The system enables additive manufacturing using laser wire deposition welding and opens up new possibilities in industries such as shipbuilding and aerospace. “Our laser robot cell not only enables the high-precision manufacturing of large components but also sets new standards in production automation and digitalization,” explains Dominik Landhäußer, Technical Sales at Nagel Technologies. “One of the greatest challenges was the integration of the concrete safety enclosure, specially developed for laser protection.”
The custom-designed and cast enclosure consists of individually engineered elements and measures 8,000 x 10,000 x 5,000 mm. Inside, two robots operate on a linear axis: one equipped with a camera system for process monitoring, and the other with the laser system for deposition welding. Components are printed on a swiveling table, with a total of 14 servo axes in use. The system accommodates workpieces up to 4,000 x 1,000 x 600 mm in size.
Impact on Research and Industry
Nagel Technologies was selected as the sole supplier of the laser robot cell through a competitive Europe-wide tender process. The combination of concrete enclosure, robotics, and laser technology posed a complex technical challenge. The partnership with SCALE provides tangible advantages:
- The laser robot cell serves as a showcase installation and can be visited by potential customers.
- Scalable production systems are tested and further developed, particularly for large structural components.
“For us, the collaboration with SCALE is a strategic move,” says Frederik Diemer, Project Manager at Nagel Technologies. “Today’s research partners are tomorrow’s customers. At the same time, we’re expanding our expertise in laser technology – from laser roughening to laser coating and laser 3D printing with wire.”
Another major benefit of the partnership: industrial prototypes are manufactured directly on the laser robot cell. By depositing material onto simplified base geometries, machining times and material costs can be significantly reduced. The process also opens up entirely new design possibilities, especially for components with complex internal geometries, cavities, and cut-outs.
Research with a Future Focus
Applications for further funded projects are already underway, particularly in the field of large-scale aerospace components. The insights gained at SCALE may lay the groundwork for next-generation manufacturing processes – shaping the future of industrial production.
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