IQONIC · Project

Zero-Defect Manufacturing Platform That Cuts Optoelectronics Production Costs and Enables Recycling

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iqonic-h2020.eu

Imagine you run a factory making LED lights, laser components, or solar panels. Every time a customer wants a slightly different product, you have to stop, retool, and restart — burning time and money. IQONIC built a smart manufacturing platform that watches every step of production, catches defects instantly, and makes it easy to switch between product types. On top of that, it figured out how to take old optoelectronic parts apart and feed them back into production, so less ends up in the landfill.

By the numbers

22%

Increase in in-service efficiency

16%

Faster reconfiguration times

10%

Reduction in production costs through recycled components

400

New jobs projected (4-year horizon after project end)

39 MEUR

Projected ROI for the consortium

Industrial demo sites

Scalable strategies at component, workstation, and shopfloor level

Partners across 7 countries

SMEs in the consortium

The business problem

What needed solving

Optoelectronics manufacturers — companies making LEDs, lasers, solar cells, and optical sensors — face a painful tradeoff: customers want more customised products, but every product changeover means downtime, new defects, and wasted materials. At the same time, rising sustainability regulations demand that end-of-life components be recovered and recycled, which most production lines simply aren't designed to do.

The solution

What was built

IQONIC delivered a zero-defect manufacturing platform with inline quality sensing, IoT-based automatic data collection, and optimised process chains covering design, assembly, disassembly, and recycling of optoelectronic components. The platform includes a prototype IoT data acquisition system and was validated across 4 industrial demo sites with 26 total deliverables.

Audience

Who needs this

LED and OLED module manufacturers struggling with defect rates during product changeoversSolar cell producers looking to recover and reuse expensive photovoltaic materialsLaser component makers needing faster reconfiguration for custom ordersElectronics recycling companies seeking automated disassembly technologyContract manufacturers in photonics who serve multiple customers with varying specifications

Business applications

Who can put this to work

LED and Lighting Manufacturing

mid-size

Target: LED module producers and smart lighting manufacturers

If you are an LED manufacturer dealing with high scrap rates and slow changeovers between product variants — IQONIC developed a zero-defect manufacturing platform with inline sensing and IoT data collection that catches quality issues before they become waste. The project demonstrated 16% faster reconfiguration times and 10% reduction in production costs through recycled components across 4 demo sites.

Photovoltaic and Solar Panel Production

enterprise

Target: Solar cell and module manufacturers

If you are a solar panel producer struggling with quality consistency and material waste — IQONIC created optimised process chains for optoelectrical components that increase in-service efficiency by 22%. The platform covers design through disassembly, letting you recover and reuse expensive photovoltaic materials instead of discarding them.

Industrial Laser Systems

SME

Target: Laser component manufacturers and system integrators

If you are a laser optics manufacturer facing pressure to customise products faster while keeping defects near zero — IQONIC delivered hardware and software components that plug into existing factory systems via IoT. With 8 scalable strategies at component, workstation, and shopfloor level, the platform handles the growing demand for individualised laser products without sacrificing quality.

Frequently asked

Quick answers

What would it cost to implement this in my factory?

The project data does not include specific licensing or implementation pricing. However, the consortium projected over 39 MEUR ROI within 4 years after the project ended, and a 10% reduction in production costs through recycled components and materials — suggesting the investment pays for itself through waste reduction and efficiency gains. Contact the consortium for pricing details.

Can this scale to my production volume?

Yes. IQONIC was specifically designed as a scalable platform with 8 strategies operating at three levels: individual component, workstation, and full shopfloor. It was validated across 4 demo sites covering a wide range of products and processes, from small-batch custom optics to higher-volume production.

What about intellectual property and licensing?

The project was coordinated by Fraunhofer, Germany's largest applied research organisation, with 18 partners across 7 countries. As an EU-funded RIA project, IP is typically owned by the partners who generated it. Licensing arrangements would need to be negotiated with the relevant consortium members.

How does this integrate with my existing equipment?

IQONIC was designed to interface with current factory facilities through IoT and data-management platforms. The prototype IoT data acquisition system collects data automatically from existing equipment. This means you don't have to rip out what you have — the platform layers on top of your current setup.

Is this proven in real manufacturing environments?

The project ran from 2018 to 2022 and demonstrated results across 4 demo sites with real industrial partners. With 12 industry partners (including 10 SMEs) in the consortium, the technology was tested in actual production settings, not just lab conditions.

Does this help with sustainability and circular economy requirements?

Yes. IQONIC specifically covers disassembly and reintroduction of components into the value chain. The project achieved a 10% reduction in production costs through recycled components and materials, directly supporting circular economy goals and upcoming EU regulations on electronics waste.

Consortium

Who built it

The IQONIC consortium is heavily industry-driven: 12 out of 18 partners come from industry (67%), including 10 SMEs, which signals strong commercial intent behind the research. Fraunhofer — Europe's largest applied research organisation — leads the project, lending serious credibility to the engineering quality. The consortium spans 7 countries (CH, CZ, DE, EL, FI, IT, UK), giving the platform exposure to different manufacturing cultures and regulatory environments. With only 4 universities and 2 research organisations rounding out the team, this is not an academic exercise — it was built by and for manufacturers.

SENSAP SWISS AGparticipant · CH
HOLONIX SRLparticipant · IT
PRIMA ELECTRO SPAparticipant · IT
IDRYMA TECHNOLOGIAS KAI EREVNASparticipant · EL
CORE INNOVATION AND TECHNOLOGY OEparticipant · EL
FYZIKALNI USTAV AV CR V.V.Iparticipant · CZ
TAMPEREEN KORKEAKOULUSAATIO SRparticipant · FI
POLITECNICO DI MILANOparticipant · IT
BRUNEL UNIVERSITY LONDONparticipant · UK
ALPES LASERS SAparticipant · CH
ATLANTIS ENGINEERING AEparticipant · EL
BRIGHTERWAVE OYparticipant · FI
FICONTEC SERVICE GMBHparticipant · DE
SACMI COOPERATIVA MECCANICI IMOLA SCparticipant · IT
CRIT CENTRO DI RICERCA E INNOVAZIONE TECNOLOGICA SRLthirdparty · IT
THE SHADOW ROBOT COMPANY LIMITEDparticipant · UK

How to reach the team

Fraunhofer Gesellschaft (DE) — reach out via their technology transfer office or request introduction through SciTransfer

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Next steps

Talk to the team behind this work.

Want to explore how IQONIC's zero-defect platform could fit your production line? SciTransfer can arrange a direct introduction to the right consortium partner for your specific manufacturing challenge.

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