Dr. Daniel Holder leads System Engineering

Dr. Daniel Holder is coming full circle. His PhD at the University of Stuttgart’s Institut für Strahlwerkzeuge (IFSW) focused on modeling, monitoring, and scaling of laser micromachining processes. Then, after splitting his time between leading IFSW’s precision machining group, and at ARENA2036, he’s back to head the system engineering department full time.

“I feel really blessed that I’m now allowed to work here again and in this position. There’s a lot of trust from Thomas Graf and Andreas Michalowski. And all the great colleagues – it’s wonderful. I really love working here.”

“The institute is renowned for the quality of its publications and its PhD student talks. We have really good scientists here, and we want to enable them to develop and grow, so that they can do really high-quality research.” Daniel says he’s determined to maintain and push the scientific excellence at IFSW forward – by applying his experience in laser materials processing, research strategy, and collaborative projects. “The internal reviews at the IFSW are demanding, it’s true. But we value quality over quantity. We’re then able to validate this through the outcomes we can demonstrate together with industry, and in collaborations with third parties.”

“From laser sources to applications and back”. IFSW is split into three departments – but emphasizes a holistic approach. Similarly, our new head of department wants to build bridges between disciplines, and between academia and industry, to tackle difficult challenges in manufacturing. It’s not just in the laser world: real world problems such as climate change require different domains to work together. Daniel points out that sometimes you can only get so far in academia by working on models and demonstrations. But when you can collaborate with industry, together you can work on a real solution that has a business model behind it.

Daniel’s vision is a group that develops not only outstanding laser processes, but complete intelligent manufacturing systems – by integrating physics, automation, software, and artificial intelligence into next-generation production technologies.

“From my own experience in the lab, a lot of it was hands-on, trying, moving, and measuring, which required a lot of manual steps, where errors can potentially occur.” In this case, AI and automatization can help reduce the potential for human errors and ensure more controlled environments.

Daniel details one example: “In ultrafast laser processing, a variety of sensors are already available to monitor process variables such as ablation depth, plasma emission, or material composition. However, the main challenge is no longer the measurement itself, but the effective integration of sensor data into the machine control system. Measurements only become valuable when they are translated into actionable control parameters.

For example, a material recognition sensor can detect transitions between different layers in a multi-material component. While the first task of the sensor is to identify changes in the material, the next step is to use this information for real-time process control. Based on the sensor feedback, the machine can either stop automatically when an unexpected material change is detected, or adapt its machining strategy accordingly. When the process reaches the interface between two material layers, the processing parameters can be adjusted dynamically to prevent damage to the underlying material while maintaining the required machining quality.

The integration of sensing, machine control, and adaptive parameter adjustment represents a key element of intelligent manufacturing. Such closed-loop control systems enable automated decision-making and dynamic process adaptation, ultimately ensuring consistent and high-quality machining results.”

Daniel also aims to create an open environment where people can develop their strengths, challenge established ideas, and enjoy working together on ambitious research. “Auf Augenhöhe” – literally “at eye level.” He wants to act as an enabler for team members to achieve the best they can. “People here are very self-motivated. We give them the tools, and they can go for it. There’s a lot of trust, and responsibility.” Daniel says the freedom at IFSW is why he came back. “I enjoy working in an environment that encourages learning and professional growth.”

Heads of departments at IFSW are responsible for the strategic and operational leadership of the department. That includes shaping the research strategy, leading people and resources, coordinating major research projects and partnerships, and ensuring the successful integration of research, teaching, and innovation. Furthermore, they act as a connecting layer between the directors and the PhD students in the three teams. At IFSW, PhD students attend internal seminars from within their own, but also other departments. This broadens their horizons, feeds the holistic team spirit, and builds on scientific excellence. “IFSW graduates are sought-after, because they also know a lot outside of the scope of their PhD thesis,” Daniel says. “And they’re curious about other stuff. If you don’t know how to solve something yourself, you’ve maybe heard of something that might help, or know who to ask.”

Finally, let it be noted that Daniel bakes a delicious plum cake – with his own hand-picked plums. It’s a reflection of his hands-on approach – which is indeed well-received by the team! You can contact him here.