3D OptiLock

Development of lightweight and safe auto-lock components

The overarching goal of the "3D Opti Lock" project is the development of an innovative hybrid manufacturing process chain for the optimization of safety-relevant metal components. The focus is on auto-lock components for vertical rope climbing systems, which, as safety-critical elements, perform an important function in preventing fall risks.

The project is being conducted during the funding period from August 1, 2025, to July 31, 2027, in close cooperation between the Technical University of Applied Sciences Wildau (TH Wildau) and Ferrocon GmbH. By combining the scientific expertise of TH Wildau with the application-oriented and manufacturing experience of Ferrocon GmbH, a practice-oriented development approach is created that takes both design and manufacturing issues into account.

Within the scope of the project, traditional subtractive manufacturing methods are combined with modern additive technologies. The goal is to realize lighter, stronger, and more resource-efficient components without compromising the safety and functionality of the auto-lock component. In doing so, new materials, lightweight structures, and generative design approaches are investigated and evaluated.

A central component of the project is the development of an improved design for the auto-lock component. Through digital design methods, FEM simulations, and topology optimization, load-adapted geometries are to be developed that enable a significant weight reduction while simultaneously meeting stringent safety requirements. Additive manufacturing is used in particular for the rapid production of prototypes as well as for iterative design optimization.

This allows different component variants to be efficiently implemented, tested, and further developed. The results obtained will subsequently be transferred to traditional manufacturing processes, such as casting, to enable economical and near-series production.

TH Wildau contributes its expertise in the fields of design, simulation, additive manufacturing, and component optimization. Ferrocon GmbH supports the project with its industrial experience in the manufacture and processing of metallic components, as well as in evaluating manufacturing feasibility. The cooperation between the two project partners enables an end-to-end approach, ranging from development and prototype manufacturing to practical application.

The following goals have been defined for the duration of the project:

• Analysis and evaluation of existing auto-lock components regarding material, geometry, function, and manufacturing

• Development and simulation of optimized component designs using FEM and topology optimization

• Production and testing of prototypes through additive manufacturing

• Investigation of suitable materials for hybrid manufacturing processes

• Transfer of optimized designs back into traditional manufacturing methods

• Assembly and testing of a functional demonstrator of an auto-lock system

• Validation of the process chain as well as the overall system under real operating conditions

Through the close cooperation between TH Wildau and Ferrocon GmbH, a hybrid process chain is to be created that combines the design freedom of additive manufacturing with the economic efficiency of traditional manufacturing methods. The project thus contributes to the development of safer, lighter, and more sustainable metal components for modern vertical rope climbing systems.

Grant number: 16KN112402

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