Fiber-reinforced composites are demanding: small quantities, a lot of manual work, little standardization. Seamless data collection is crucial for the quality and traceability of production. This is precisely where the digital lightweight construction laboratory at the Institute of Aircraft Design (IFB) at the University of Stuttgart comes in – in collaboration with the industrial IoT specialist Cybus. Using a scalable data platform, machine data is collected, networked and made usable. The result: flexible, data-driven and scalable production – ideal for prototypes, small series and industrial applications – even beyond the aviation industry.
The IFB is regarded as a leader in lightweight construction. Together with Cybus, the institute is showing how networked systems and scalable, standardized data platforms are opening up new avenues for manufacturing. Cybus develops comprehensive solutions for data integration – especially for industrial companies.
Fiber-reinforced composites: High effort, little digitalization
Fiber-reinforced composites with carbon or glass fibers are indispensable for aviation. They provide high stability with minimal weight – perfect for energy-saving aircraft operation. But their processing is complex:
- highly fluctuating quantities
- manual, partially and fully automated processes
- quick adaptation to new production lines necessary
- lack of standardization in IT-based data collection
- legal requirements for CO₂ balancing require a reliable data platform for sustainability certificates
- increasing requirements for traceability and circular economy, which make seamless data collection essential
- to build a comprehensive picture, CAD models, simulation data, process parameters, and environmental information must be intelligently connected
Paper-based processes and isolated IT systems are increasingly reaching their limits. Lightweight construction using carbon, Kevlar, or glass fibers requires digitalization. This calls for a platform that reliably collects and connects machine data — especially in non-standardized manufacturing environments.
Key challenges at a glance:
- manual and paper-based data collection
- low efficiency and lack of scalability in manufacturing processes
- insufficient transparency of production and environmental data
- lack of traceability and quality issues
The digital lightweight construction lab as a data source
The Institute of Aircraft Design (IFB) at the University of Stuttgart operates a state-of-the-art digital lightweight construction laboratory. This is where fiber structures and components with precise fiber architecture and complex geometries are created. They test new materials and research their recyclability. The laboratory continuously collects data: machine data, images, videos and environmental parameters such as temperature, humidity and air pressure. All equipment and sensors are connected and digitally linked. The goal is to capture a complete picture of every process — from concept to implementation.
Connectware: scalable data infrastructure for research and industry
In collaboration with Cybus, the IFB has developed a solution that systematically collects machine data and analyzes it in real time — tailored to the highly specialized and variable requirements of lightweight construction.
Cybus Connectware functions as a central factory data hub that collects, processes, and distributes machine data. The platform supports complex configurations across multiple sites, is highly scalable, and provides direct access to real-time data from both IT and OT systems. Special emphasis is placed on configurability and adaptability — ideal for dynamic experimental environments.
shepard: context data for greater transparency and traceability
A core feature is shepard — an open, multi-database storage system that records contextual information and connects it to machine data. shepard is the system of choice for building a data lakehouse at the IFB. Over the long term, all time-based production, environmental, and sensor data will be aggregated here — enabling full traceability and data-driven optimization.
Engineers can start experiments directly at the machine using a tablet, enter specific parameters, and compare process variants. The tablet also allows additional inputs such as annotations, images, and pricing adjustments — i.e., all manual information — to be automatically connected to the respective experiment. shepard thus provides a data-driven foundation for root cause analysis, continuous quality assurance, and targeted process optimization.
Opportunities for industry partners: safely testing new technologies
The digital lightweight construction lab also serves as an industrial data and experimentation platform — open to collaborations with industry partners. Companies gain access to a modern infrastructure to:
- systematically collect machine data
- analyze processes based on data
- test new technologies
- implement pilot projects and prototypes
- reduce time-to-market
This offering is especially attractive for SMEs without their own data platforms, enabling them to test new technologies in secure, low-risk environments. Projects can be carried out either as direct commissions or within publicly funded programs. ms. The lab’s open structure allows for close involvement of industry partners from the early stages of product development.
More flexibility and transparency through integrated systems
The project is built on a deep understanding of the requirements of lightweight construction: production lines must be scalable from batch sizes of 10 to several thousand. Manual, semi-automated, and fully automated processes are intelligently combined.
Key benefits of the digital setup:
- significantly improved data quality
- reduced development time through virtual testing
- structured, traceable, and fail-safe documentation
- greater flexibility: the same infrastructure for both prototypes and series production
Data flows back into process development and forms the basis for continuous improvement — leading to a better understanding of both processes and product life cycles. It also enables targeted control and a new level of transparency.
The digital lightweight construction lab proves: future-oriented production is digital, flexible, and sustainable — and ready for industrial scale.
Results at a glance: what the lab has achieved so far
- shorter development cycles
- improved production quality
- flexible switching between small and large batch sizes
- structured and traceable documentation
