X-ray computed tomography (CT) provides three-dimensional insights into the internal structure of materials, components and even complex microsystems. It has therefore become an essential tool across industries and applications in quality assurance and technical research and development. High-resolution detectors and powerful X-ray sources in modern micro-CT (µCT) systems enable cross-scale 3D structural analyses and measurement tasks with high accuracy. The aim of the project is to expand the research infrastructure and specific expertise through the procurement and sustainable integration of a µCT at the THU. This forward-looking expansion of instrumentation will bridge the gap with existing methods in materials microscopy and manufacturing metrology, opening up new perspectives in the research fields of materials science, manufacturing technologies, medical technology/biotechnology, reverse engineering and energy storage systems.
As part of the call for proposals "Large-Scale Research Equipment at Universities of Applied Sciences 2024" under the Baden-Württemberg ERDF Program 2021–2027 (VwV EFRE FEIH 2021–2027), the Ulm University of Applied Sciences submitted an application for the large-scale research equipment project "InSightTHU" to procure a modern, high-resolution µCT. The project was approved and funded with a total grant of €850,000, 40% of which came from EU funds of the European Regional Development Fund (ERDF) and 60% from funds of the Baden-Württemberg Ministry of Science, Research, and the Arts. The purpose of the funded large-scale research facility is to perform high-resolution, three-dimensional structural and microstructural analysis as well as component measurement in applied research at the University of Ulm, and it is thus equally available to all researchers at the university. The project is led by Prof. Dr.-Ing. Andreas Häger.
Carl Zeiss Microscopy Deutschland GmbH was awarded the contract to supply a Zeiss METROTOM 1500 G3 industrial computer tomograph in the course of a Europe-wide tendering procedure. The device is equipped with a microfocus X-ray tube with an acceleration voltage of 225 kV and a maximum X-ray power of 500 W. The detector, which is mounted at a distance of 1500 mm and has a detector area of 430 x 430 mm, provides a resolution of 3072 x 3072 pixels. The minimum focal spot size is 7 µm. This enables the device to perform high-resolution scans in the micrometer range on very small objects through to coarse structure analyses on large components with a height of up to 800 mm and a component weight of up to 50 kg. The full X-ray protection device is equipped with a range of software and hardware features to prevent image artifacts. The volume data sets are evaluated using the Zeiss INSPECT X-Ray software on a high-performance workstation. For measuring tasks, the system has a scanning deviation (SD) of 4.5 + L/50 µm and a length measurement deviation (PS) of 3 µm in accordance with VDI/VDE 2630 Sheet 1.3. The device is supervised by a specially trained team under the direction of Prof. Häger.
Together with our Zeiss SIGMA VP scanning electron microscope and the other laboratory infrastructure in the field of materials microscopy and production metrology, it forms the essential basis of the "Large-scale research center for high-resolution imaging processes and 3D metrology" currently being established at the THU.
As a large-scale research instrument, our µCT is used in various fields of applied research. Current applications primarily stem from materials science, medical technology, joining technology, and energy technology. However, the new possibilities of three-dimensional structural analysis and component measurement are generally open to all researchers at the university. We are also happy to incorporate this technology into existing and new collaborations with our regional and national partners in research and industry. Please feel free to contact the project leader, Prof. Dr.-Ing. Andreas Häger, directly with your inquiry.
Examples of some of our previous applications of computed tomography at THU:
Dental technology: High-resolution component measurement and detection of damage mechanisms in dental implants
Joining technology: Weld inspection on laser and friction stir weld joints
3D printing: Pore analysis of additively manufactured metal components (SLM, LMT, and MF3 processes)
Foundry technology: Pore analysis and 3D geometric alignment of light-metal sand-cast components
Adhesive technology: Positioning and visualization of adhesive distribution
Lightweight construction: Crack detection in CFRP components
Energy technology: Structural analysis and defect detection in lithium-ion batteries