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Less brake dust, faster development.​

How EMAG turns ZEISS Microscopy into AI-powered quality insights​
Dominic Grimminger, product manager at EMAG, beside machined brake discs, with industrial metrology and manufacturing imagery.

EMAG LaserTec is accelerating the development of coated brake discs through connected metrology and AI-powered quality analysis.​

With the Euro 7 standard driving higher requirements for brake dust reduction, EMAG LaserTec is developing laser-based coating processes designed to reduce brake disc wear.

To ensure quality across the entire process chain, the company uses ZEISS microscopy with AI-powered image analysis, complemented by X-ray technology and coordinate measuring technology. The result: reproducible quality data and significantly faster process development.​

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Dominic Grimminger, product manager at EMAG, in front of industrial manufacturing equipment and technology displays.

Dominic Grimminger, product manager for coated brake discs at EMAG, explains:​

“The speed of analysis has become a decisive factor for us. It directly determines how quickly we can move through development cycles and optimize our processes. That is why we rely on the ZEISS portfolio, which combines high-precision microscopy with standardized analysis methods and AI-powered automation. This not only gives us a high level of confidence in our quality assessment, but also significantly reduces analysis times, allowing us to optimize and further develop our processes more quickly.”

Technician operating a ZEISS microscope workstation to analyze magnified material samples.

Powder analysis: Ensuring material quality from the start​

Powder morphology​
ZEISS Scanning electron microscope and ZEISS ZEN core​

As early as incoming inspection, EMAG LaserTec analyzes the powder feedstock for particle morphology, size and grain structure. ZEISS scanning electron microscopy combined with ZEN core provides detailed insights into the physical characteristics and homogeneity of the powder.​

ZEISS software displaying an elemental map, particle analysis, and spectrum chart for materials inspection.

ZEISS ZEN core

Chemical composition​ EDX analysis​

Complementary EDX analysis identifies the chemical elements present in the powder and determines their respective proportions. This provides detailed data on the material composition and helps reveal variations between different powder batches.​

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Gloved technician positioning a small metal component in a yellow fixture for precision inspection.

Material selection​
Comparing powder suppliers​

By combining morphological and chemical analysis, EMAG LaserTec can systematically compare powders from different suppliers. The resulting data supports the selection of the most suitable feedstock for stable and reproducible coating processes.​

Technician reviewing a brake disc image and inspection parameters in ZEISS measurement software.

Base component inspection: Non-destructive detection of internal casting defects​
ZEISS Bosello 2D X-ray system​

In parallel with the powder analysis, EMAG LaserTec inspects the cast brake disc base components for internal defects. The ZEISS Bosello 2D X-ray system is used to non-destructively analyze internal defects, particularly pores and shrinkage cavities. The X-ray inspection provides reliable information on the internal quality of the base components at an early stage, creating a solid basis for the subsequent manufacturing steps.​

Technician operating a ZEISS CMM probe to inspect an automotive wheel component.

Geometry inspection: Reliably documenting dimensional accuracy​
ZEISS PRISMO and ZEISS PiWeb​

A ZEISS PRISMO coordinate measuring machine checks relevant geometric features of the brake disc. ZEISS PiWeb centrally documents, visualizes and analyzes the measurement results. This provides traceable quality data that makes it easier to compare different development stages.​

ZEISS arivis Cloud interface displaying annotated microscopy imagery with classified pores, carbide, and background regions.

ZEISS arivis and ZEISS ZEN core​

AI-powered analysis: From more than an hour to just a few minutes​

To enable faster and more reproducible cross-section analysis, EMAG LaserTec uses AI-powered automation. AI models trained in ZEISS arivis are integrated into ZEN core, where they perform standardized analysis of coating thickness and material proportions.​ Previously, image acquisition, analysis and documentation of a cross-section with 21 measurement points took more than an hour. Today, the entire process is automated and completed within a few minutes. This allows coating variants to be evaluated more quickly and development cycles to be shortened.​

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Technician examining a sample with a ZEISS Axio Imager microscope in a laboratory.

Coating and layer analysis: Assessing quality in detail​

ZEISS Axio Imager and ZEISS ZEN core​

After laser-based coating, EMAG LaserTec examines prepared cross-sections using the ZEISS Axio Imager and ZEN core. The analysis focuses on coating thickness, carbide content and distribution, porosity, cracks and material phases.​ 

ZEISS software measuring coating and bonding layer thickness in a metallographic image.

ZEISS Axio Imager and ZEISS ZEN core​

Trained AI models automatically analyze the captured images and perform the standardized evaluation. This enables consistent, reproducible assessment of coating quality and provides valuable insights for the targeted optimization of process parameters.​

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Markus Braig, application engineer at EMAG, standing in a manufacturing facility.

Markus Braig, application engineer at EMAG explains:​

“Previously, analyzing a cross-section image with 21 measurement points, including documentation, took us more than an hour. Today, image acquisition, analysis and report generation are completed automatically within a few minutes – while delivering even higher quality.”

Close-up of an EMAG brake disc with machined surface and engraved logo.

End-to-end quality assurance for the brake disc of the future​

From material analysis to automated coating evaluation, EMAG LaserTec combines different ZEISS technologies into a comprehensive quality strategy. Precise and reproducible measurement results enable targeted process optimization and create the foundation for the future series production of coated brake discs.​

The key benefits: less time spent on quality analysis, faster development cycles and a reliable data foundation for low-wear brake discs.​