wbk Institute of Production Science

Sven Roth, M.Sc.

  • Campus Süd

Sven Roth, M.Sc.

Area of Research:

  • Joining technologies for multi-material-design
  • Lightweight Manufacturing in the field of hybrid composites
  • Manufacturing technologies for hybrid laminates
  • Automation solutions for the manufacturing of electromotors
  • Human-robot solutions for assembly tasks


General Tasks:

  • Coordination of lecture Automated Assembly as part of the Production Techniques Laboratory
  • Supervision of Bachelor and Master theses
  • Supervision of experimental workshops in the field of production technology



  • FMEL - Fiber-Metal-Elastomer Laminates – a novel, sustainable material concept for the vehicle construction
  • GuLaMasch – Investigation of the technical potential of using Fiber-Metal-Elastomer Laminates in machine tools
  • SPP1712 – Intrinsische Hybridverbunde für Leichtbautragstrukturen
  • Industrial cooperation in the field of machine tools – Lightweight solutions for structural applications
  • Industrial cooperation in the automotive area – Joining technologies for multi-material-design applications
  • Industrial cooperation in the automotive area – Manufacturing of electric motors


Test benches:


Dissertation: Damage-free joining of hybrid FRP/metal components to metallic structures by the use of resistance spot welding


Curriculum Vitae:

since 09/2015 Research Associate at the Institute of Production Science (wbk) at Karlsruhe Institute of Tech-nology (KIT)
10/2009 - 09/2015 Study of Mechanical Engineering at the Karlsruhe Institute of Technology (KIT)



[ 1 ] Fleischer, J.; Roth, S. & Sommer, C. (2016), "Faser-Metall-Gummi-Hybridlaminate", ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb, no. 9, pp. 483-486. 10.3139/104.111577
Die steigenden Anforderungen aus dem Umwelt- und Klimaschutz an die Automobilbranche verlangen zunehmend eine wirtschaftliche Umsetzung des Leichtbaus bei der Fertigung neuer Fahrzeuge. Die hierbei verwendeten Leichtbaumaterialien entsprechen jedoch meist nicht den Ansprüchen an das akustische Verhalten und den damit einhergehenden Komfort. Eine Möglichkeit zur Verringerung der Fahrzeugmasse bei gleichzeitig hohen Dämpfungseigenschaften besteht in der Verwendung von Faser-Metall-Gummi-Hybridlaminaten. Dieser Beitrag stellt einen Ansatz vor, welcher eine ökonomische Herstellung der neuartigen Hybridlaminate ermöglicht. Der Herstellungsprozess wurde an unterschiedlichen Bauteilgeometrien erprobt und zudem der Einfluss des eingebrachten Elastomers auf das Umformverhalten des Werkstoffkonzepts untersucht.

[ 2 ] Roth, S.; Coutandin, S. & Fleischer, J. (2019), "New Production Technologies - Material- and Process Characterization of Fibre-Metal-Elastomer Laminate Components with high forming degrees" in Technologies for economical and functional lightweight design, eds. Dröder, K. & Vietor, T., Springer Verlag, Berlin, pp. 147-154. ISBN/ISSN: 3662582066
Hybrid material concepts provide a high variability in the resulting part properties, and thus are often applied to satisfy multiple component demands. Fibre-metal laminates (FML) are widely spread in aerospace applications and are being used for decades as they show a high lightweight potential and a good fatigue behaviour. However, a broad conventional use of hybrid laminates in the automotive sector is not existing until today. The high manufacturing costs, caused by the surface pre-treatment of the metal layer, as well as long process cycles and a limited formability of current laminates are not suitable for automotive applications. This paper presents an approach, which allows the processing of hybrid laminates for high-volume applications and enables high forming degrees of the manufactured parts. As an additional elastomer layer is used to separate the metal from the fibre reinforced layer, carbon fibre reinforced polymers (CFRP) can be used instead of conventional glass fibres, preventing a galvanic corrosion between carbon and the metal. In addition to the manufacturing process itself, the influence of the formability will be discussed with regards to the distribution of the laminate layers, determining achievable forming degrees of the manufactured fibre-metal-elastomer laminate (FMEL) specimen. The laminate behaviour during the forming of the uncured laminate will be described by analysing micro sections. Furthermore, the results of an experimental modal analysis will be presented in order to determine the damping properties of the investigated hybrid laminates.

[ 3 ] Muth, M.; Bernath, A.; Seuffert, J.; Roth, S.; Coutandin, S.; Fleischer, J.; Henning, F. & Weidenmann, K. A. (2019), "LOAD-BEARING FVK METAL HYBRID STRUCTURE FOR AUTOMOTIVE CRASH APPLICATIONS - SIMULATION, PRODUCTION, PERFORMANCE". 23rd Dresden International Lightweight Engineering Symposium, eds. Institut für Leichtbau und Kunststofftechnik, T. U. D., pp. 0-0.
Designing with CFRP, innovative joining technologies are needed to exploit the potential of lightweight constructions. Metallic inserts represent one of these joining technologies. In contrast to screw and rivet joints cutting of the fibres is prevented during joining by guiding the fibres around the inserts shaft. The CFRP/metal composite with inserts however, has been little investigated so far. In order to be able to compare such components to a CFRP/metal composite with adhesive bonded parts investigations are donefor both types of components.

[ 4 ] Roth, S.; Stoll, M.; Weidenmann, K. A.; Coutandin, S. & Fleischer, J. (2019), "A new process route for the manufacturing of highly formed fiber-metal-laminates with elastomer interlayers (FMEL)", The International Journal of Advanced Manufacturing Technology, pp. 1293-1301. 10.1007/s00170-019-04103-4
Fiber-metal-laminates (FML) provide a high variability in part properties and are often used to satisfy multiple component demands in aerospace applications. However, conventional use of hybrid laminates in the automotive sector is unrewarding due to high manufacturing costs and strongly restricted forming degrees. This paper presents an approach, which enables the manufacturing of laminate components with low bending radii for high volume applications. To separate the carbon fiber–reinforced polymers (CFRP) from the metal sheets, an elastomer layer was used, resulting in the omission of surface treatments for adhesion and corrosion prevention. The forming degrees presented in this work exceeded current approaches. Furthermore, the influence of the forming process on the mechanical properties was analyzed, thus ensuring the profitability of the presented approach for industrial applications.

[ 5 ] Roth, S.; Warnck, M.; Coutandin, S. & Fleischer, J. (2019), "Herstellung punktschweißbarer CFK-Metall-Bauteile im RTM Prozess", Lightweight Design, vol. 5, pp. 18-23. 10.1007/s35725-019-0047-1
Das wbk Institut für Produktionstechnik entwickelt einen Herstellungsprozess im RTM-Verfahren, der eine fasergerechte Einbringung schweißbarer Krafteinleitungselemente in Faserverbundbauteile ermöglicht. Dies erlaubt ein einfaches Fügen an Stahlkomponenten mittels konventionellem Punktschweißen und eröffnet neue Möglichkeiten für Karosserieanwendungen im Multi-Material-Design

[ 6 ] Rothaupt, B.; Roth, S.; Yu, L. & Fleischer, J. (2020), "Fibre-metal elastomer laminates – Lightweight components with superior damping characteristics", JEC Composites Magazine, pp. 151-153.
In the development of machine tools, the most important values to ensure competitiveness are machine performance and accuracy. Both are affected significantly by the specific mass-related stiffness and the damping properties of the engineering materials used. Fibremetal elastomer laminates (FMEL) provide an outstanding property profile. However, they are not implemented industrially as a suitable process for manufacturing structural FMEL components has not been identified so far.

[ 7 ] Roth, S.; Pracisnore, F.; Coutandin, S. & Fleischer, J. (2020), "A new approach for modelling the fibre path in bolted joints of continuous fibre reinforced composites", Composite Structures, pp. 0-0. 10.1016/j.compstruct.2020.112184
A fibre conform hole forming into continuous fibre reinforced components leads to beneficial part properties, as the fibre structure is not damaged in comparison to a drilling operation due to a reorientation of the fibres during the preforming process. To determine precisely the local component properties of the manufactured composite part, detailed information about the resulting fibre paths is required. For the first time, this paper provides a universal methodology to approximate the actual fibre paths in the reoriented area around the hole. Based on a few experimental data, the developed framework allows the construction of the fibre pathways depending on the formed hole diameter and the used fabric type. Two models based on polynomial splines are developed and compared with regards to the achievable model accuracy. The overall methodology is evaluated using different hole diameter and fabric types. Here, a very good correlation between approximation and reality is observed.

[ 8 ] Roth, S.; Hezler, A.; Pampus, O.; Coutandin, S. & Fleischer, J. (2020), "Influence of the process parameter of resistance spot welding and the geometry of weldable load introducing elements for FRP/metal joints on the heat input", Journal of Advanced Joining Processes, pp. 100032. 10.1016/j.jajp.2020.100032 [30.11.-1].
Resistance spot welding is one of the most economical joining processes when manufacturing conventional steel bodies in the automotive sector. However, its applicability in future body constructions is limited due to the growing material mix. Since the demands of efficiency and weight reduction are steadily increasing, modern car bodies implement lightweight materials, especially fibre-reinforced plastics (FRP), in a multi-material design. To enable the joining of FRP/steel constructions with resistance spot welding, weldable inserts can be embedded in the FRP. In order to evaluate the thermal damage to the surrounding polymer, an experimental study of the welding induced heat is presented in this study. The influence of welding parameter, metal sheet thickness and alloying degree on the heat input are characterised. Based on this data, weldability lobes and energy input diagrams are derived. Furthermore, the dependency between insert geometry and the resulting temperature distribution is examined

[ 9 ] Friedmann, M.; Köse, H.; Roth, S.; Wirth, B.; Coutandin, S. & Fleischer, J. (2020), "Werkstückerkennung mit Greifsystemen", Robotik und Produktion, no. 5, pp. 32-33. [30.11.-1].
Bereits heute wird eine Fülle an Daten entlang der Wertschöpfungskette erhoben und stellenweise bereits z.B. zur Prozessüberwachung genutzt. Das Ziel dieser Entwicklung sind autonome Fertigungssysteme, die eine flexible Automatisierung unabhängig von der Losgröße ermöglichen und damit für eine hohe Produktivität sorgen. In diesem Kontext werden am wbk Institut für Produktionstechnik des Karlsruher Institut für Technologie Möglichkeiten zur Steigerung der Autonomie von Handhabungssystemen, z.B. durch eine Werkstückklassifizierung mit Hilfe der Methoden künstlicher Intelligenz, erforscht.