The 3DEMO project, funded by the German Federal Ministry of Economic Affairs and Climate Action (BMWK) under the reference 03ET1660H, ran from 1 April 2019 to 30 September 2022. INVENT Innovative Verbundwerkstoffe Realisation und Vermarktung neuer Technologien GmbH was the sole partner responsible for the emission‑monitoring component of the programme. The consortium’s cross‑industry expertise allowed INVENT to carry out all tasks internally, with no external collaboration required for its part of the work. The final report, published on 28 March 2023, summarises the technical achievements and the project’s organisational context.

The core technical outcome was a prototype system that integrates a wireless sensor network with a dynamic ventilation control strategy for the mechanical post‑processing of carbon‑fibre reinforced polymer (CFRP) and glass‑fibre reinforced polymer (GFRP). The measurement strategy began with a site survey and the selection of key parameters: particle concentration, airflow and pressure, temperature, and, where relevant, humidity. Sensor nodes were distributed throughout the machining area based on a floor plan and machine‑usage logs, balancing the need for worker‑centric monitoring against machine‑centric data. The resulting layout placed sensors near critical points such as the milling head and along the room’s airflow paths.

During the project a change in the building’s HVAC system required an update to the strategy. A mobile Vacomat unit was installed in the flat‑bed milling room. This device features two suction points: one directly at the milling head to capture freshly generated particles, and a second in the room to clean the ambient air. The sensor network feeds real‑time particle data to a pressure switch that activates the Vacomat. When the particle concentration falls below a predefined threshold, the system automatically shuts down the suction, conserving energy. In parallel, an energy‑saving valve controls the local exhaust, opening only when needed. The remaining rooms are monitored continuously; displays in each space show current particle levels, and a warning system alerts operators when concentrations exceed the safety limit, eliminating the need for respirators during normal operation.

The project also produced a three‑dimensional model of the machining rooms and a comprehensive ventilation concept. These deliverables were used to validate the sensor placement and to optimise the airflow paths. The prototype was successfully installed and tested in the target environment, demonstrating that the integrated control logic can maintain particle concentrations below the occupational exposure limits while reducing energy consumption.

In terms of collaboration, the project was executed in close partnership with the consortium’s other members, although INVENT’s tasks were largely self‑contained. The project’s timeline, funding source, and deliverables were coordinated through the project management office, with the final report submitted to the Technical Information Library in Hannover. No public presentations or publications were made during the project, but the report itself serves as the official documentation of the technical results. The 3DEMO initiative thus achieved its goal of creating a secure and energy‑efficient factory environment through 3‑D emission monitoring, with INVENT’s prototype system providing a practical example of how sensor networks can be coupled to HVAC controls to protect workers and reduce operational costs.