During the period from 1 September 2019 to 31 August 2022, the Mobile Repair Factory project, part of the WIR! program (grant number 03WIR2503A), was carried out at Brandenburg Technical University in Cottbus‑Senftenberg under the coordination of Professor Dr.-Ing. Sebastian Härtel. The project aimed to develop a mobile maintenance platform that combines additive and digital technologies for the repair of industrial components, with a particular focus on welding technology, digital integration, and the establishment of a comprehensive manufacturing and repair strategy. The overall effort was divided into three phases: planning, implementation, and field testing. In the planning phase, several container concepts were evaluated. A 40‑foot container was rejected because the PM800 machining system could not be operated in its built‑in configuration. The final design uses two 20‑foot containers that together provide a closed, safety‑compliant workshop. One container houses the PM800 machine, while the other serves as a peripheral module that contains operator stations, modular cabins for partner equipment, and connections for compressed air and gas. The modular cabins allow the installation of partner units with a maximum power draw of 32 A, and they protect equipment from process‑related contaminants through roll doors. The design also incorporates a variable roof extension of up to one metre to avoid interference with the machine spindle travel and to maximise workspace.
During implementation, the machine base, welding equipment, a rotating table, an air‑generation unit, and a smoke‑extraction system were installed. Extensive adjustments to the machine base and components ensured a seamless repair workflow. The platform integrates subtractive processes such as milling and drilling with an additive welding process. The rotating table provides multiple work positions along a linear guide that runs between the two containers, and a quick‑coupling system with a wall‑penetration concept was developed to maintain laser safety while allowing rapid connection of media. The project also introduced a self‑centering pin system to achieve precise alignment between the two container halves, and reinforced the existing container structure to support the added equipment.
The field test, conducted at the associated partner LEAG, demonstrated that the platform could successfully identify damage, plan repair paths, execute additive welding, and monitor the process in real time. The repaired components met the required quality standards, confirming that the project’s objectives were achieved. The Mobile Repair Factory therefore represents a milestone in regional industrial development, providing a scalable, mobile solution that links industry and research. The collaboration between Brandenburg Technical University and LEAG, supported by the WIR! program, showcases how digital and additive technologies can be combined in a mobile setting to deliver innovative repair solutions that strengthen the local industrial ecosystem.