Smart Thermal Processing​

Project Lead: Honeywell
Partners: Virginia Tech, Seco-Warwick

Member % Cost Share: 68.55%
CESMII % Cost Share: 31.45%
Duration: 18 Months

Problem Statement

Thermal processing equipment accounts for 61% of manufacturing onsite energy use annually, yet contain many common features and functions cutting across the spectrum of discrete part processing and continuous industrial operations. These universal practices open significant opportunity to leverage recent advances in Smart Manufacturing (SM) technologies.

Project Goal

This project will develop SM technologies for thermal processes essential to US manufacturing with a primary goal of reducing energy consumption by 20%, improving processing yields by 10%, and reducing gas consumption by 10%. 

Technical Approach

This project is structured into 3 primary tasks:

  • creating a Smart Thermal Processing implementation strategy
  • executing initial SM sensor, monitoring and data analytics development in three thermal processing areas: deposition & coatings, heat treatment and brazing 
  • manufacturing readiness trials in working manufacturing facilities. 

Deliverables/Outcomes/SM Marketplace

  • Identified energy use reduction opportunities of Part Load Optimization (PLO), Sensing, and Predictive Health (PH) technologies
  • Implemented Part Load Optimization (PLO), Sensing, and Predictive Health (PH) technologies at Honeywell South Bend carbon brake disc manufacturing plant
  • Conducted production trials at Honeywell facilities to validate PLO, Sensing and PH technologies for chemical vapor infiltration brake manufacturing
  • Predictive modules for thermal processing
  • Part Load Optimization Application
  • Chemical Reaction Control Application
  • Predictive Health Application

Potential Impact

The CESMII investment in this project will accelerate the use of SM in thermal processes providing the seed money to kick start development and commercial implementation. The CESMII collaboration will enable cross-process innovations focused on thermal processing functionalities that cut across coatings and heat treatment


  • Draft Strategy and Roadmap for implementing Smart Thermal Processing into US manufacturing
  • Creation of core software profiles/applications to be hosted on the CESMII platform accessible by the thermal processing industry

Project Selection & Announcements


Leverage project outcomes for your manufacturing operations

Learn More