Fraunhofer ILT and Etxetar advance LMD and EHLA adoption
The Fraunhofer Institute for Laser Technology ILT (Fraunhofer ILT), based in Aachen, Germany, and Etxetar, located in Elgoibar, Spain, are expanding the industrial adoption of Laser Metal Deposition (LMD) and extreme high-speed laser material deposition (EHLA). Under a memorandum of understanding, the partners will combine process expertise, industrial engineering and application know-how to support applications in aviation, coating technologies and other industrial sectors.
Etxetar develops high-value industrial solutions that combine machine-tool expertise with application-focused engineering. In laser powder directed energy deposition (LP-DED), the company has experience in turbine blade and blisk repair, railway axles and gear components, supported by proprietary process strategies, process monitoring and industrial software integration.
Fraunhofer ILT contributes extensive expertise in LMD and EHLA process development, system design and digital process optimisation. Its capabilities include in-process geometry measurement, deviation detection and automatic parameter adjustment, helping manufacturers achieve consistent quality while adapting established processes to new applications.
A key driver for wider adoption is regulation. Europe’s Euro 7 framework now addresses non-exhaust emissions, including brake particle emissions, increasing demand for scalable coating technologies. Etxetar has already positioned EHLA-based solutions to address these requirements.
“Euro 7 is creating a demand for scalable coating solutions – and that pressure will not stay limited to Europe. We expect similar requirements to emerge in other major markets,” said Dr Thomas Schopphoven, Head of Department Laser Material Deposition at Fraunhofer ILT.
According to Fraunhofer ILT, once legislation creates a clear technical need, manufacturers begin looking for practical alternatives, creating opportunities for broader deployment of coating technologies in markets including China, India and Japan.
Aviation is a key focus for the partnership. Components such as blisks and turbine blades combine high material value, demanding operating conditions and a strong incentive to extend service life through repair rather than replacement.
“Aviation sets the bar for what laser-based repair has to deliver – precision, repeatability and full process control on components where failure is not an option,” said Alejandro Bárcena, CEO of Etxetar.
Beyond aviation, the partners see opportunities in gear repair, certified railway axle repair and space-related applications, where advanced manufacturing and repair strategies can reduce costs and extend component life.
Digitalisation and artificial intelligence are expected to support wider industrial deployment. Fraunhofer ILT’s AI-SLAM project enables real-time geometry measurement, contour deviation detection and automatic process adjustment during coating and repair operations. By learning from process data, the system can improve consistency and reduce manual intervention, helping manufacturers scale laser-based repair and coating processes more efficiently.
The collaboration aims to accelerate the industrial deployment of LMD and EHLA in markets where regulation, durability requirements and cost pressures are driving demand, from Euro 7-compliant brake disc coatings to the repair of high-value turbine components.
