Precise Radar and Sensor Systems for Stable Processes and Highest Product Quality

Radar-based sensor systems enable the targeted measurement, evaluation, and control of industrial processes—particularly in specific sector applications where optical methods reach their physical limits. The focus is on dedicated industrial fields such as steel processing, food production, surface treatment, and additive manufacturing. For these applications, Fraunhofer FHR develops tailored solutions that are aligned with real process conditions.

The sensor technology operates reliably under demanding conditions such as high temperatures, steam, dust, or contamination and enables measurements even through materials. This provides actionable, in-process information on material states, geometries, and deviations, enabling early intervention.

Industries and Specific Application Areas

The key strength of radar-based systems lies in their adaptability to specific production processes. Typical application areas include:

Steel Industry and Heavy Industry

In rolling mills and related processes, radar sensors enable precise measurement of the width, thickness, and shape of steel products—even under extreme conditions such as scale formation, high temperatures, or spray water. This enables robust 100% inspection, reducing scrap rates and preventing equipment damage.

Further Information: Steel Industry

Food Production

Radar-based inspection methods support quality assurance along the entire process chain—from filling to packaging. Contaminants, air inclusions, or moisture can be detected at an early stage, preventing defective products from entering the market.

Surface Treatment and Coating Processes

Fine layer thicknesses, material transitions, and surface structures can be analyzed directly during operation. This enables real-time adjustment of process parameters and ensures consistently high quality standards.

Additive Manufacturing

Radar enables rapid and comprehensive evaluation of additively manufactured components immediately after printing. In addition to surface quality, internal structures can be assessed without damaging the component.

Intelligent Surfaces (“Smart Skin”)

Flexible radar sensor systems integrated into materials open up new possibilities for machinery and equipment. As “intelligent surfaces,” they enable condition monitoring, self-diagnosis, and interaction directly at the machine level, including retrofit applications.

Non-Destructive Testing in Production Processes

Non-destructive testing is a core capability of radar-based systems. Materials and components can be analyzed on, within, and through structures without interrupting ongoing processes. This enables early quality decisions during production and contributes to long-term process stability.

Development of Application-Oriented Solutions

At Fraunhofer FHR, the focus is not on generic technologies but on application-specific solutions for concrete industrial challenges. Development ranges from initial feasibility studies and prototypes to demonstrators in real production environments. The objective is to make the added value visible at an early stage and to systematically transfer solutions into practical application.

The deployed sensor systems are consistently designed to deliver measurable benefits within specific industries. They enable more precise process monitoring, reduce scrap, and support stable, reproducible production processes. At the same time, they provide the foundation for further automation and data-driven optimization.