Not for late risers, made for doers

At Smart Material GmbH, the doors open before sunrise. By 6:00 AM, production floors are already lively with activity. What immediately stands out is not just the presence of sophisticated machinery, but the pivotal role of manual craftsmanship —a blend of precision, patience, and skill. Despite the focused work, the atmosphere remains relaxed; a radio quietly plays current hits in the background. Only a keen eye can sense the high-tech materials being molded and handled here.

A Clue on the Wall

Smart Materials Across All Elements

Piezo ceramics command a unique position among smart materials: they deform under applied voltage (inverse piezoelectric effect) and generate voltage when mechanically stressed (direct effect). Applied to the leading edge of an aircraft wing, a voltage-triggered piezoceramic can produce micro vibrations that mechanically dislodge ice.

These materials also serve on land—for instance, as parking sensors in vehicles—and even underwater. One of the most remarkable and unconventional uses is their implantation in fish. At first glance, this may seem unusual, but it serves a vital ecological purpose: to power tracking transmitters embedded in trout navigating river systems altered by humans. A tiny 300 µm-thin piezoelectric component harvests energy from the fish's swimming motions, enabling accurate monitoring where power is otherwise hard to provide.

Handcrafted series production

At the heart of Smart Material’s operation lies the Macro Fiber Composite™ (MFC)—a design devised by NASA engineers in 1999 and licensed to Smart Material since 2002. MFC components require meticulous assembly by hand. The process unfolds in three main stages:

1. Slicing piezoceramic wafers with precision saws into rectangular fibers
2. Layering polyimide films, electrodes, and adhesives
3. Laminating and polarizing the composite under controlled heat to activate its piezoelectric response

Technicians align ceramic fibers using specialized templates to form 1 3 piezo composites, which are infused with epoxy, sliced to precise thicknesses, and polarized. It’s delicate, demanding work, requiring steady hands and sharp eyes. Once assembled, the “packages” are encapsulated via casting and vacuum processing into thin sheets—then delicately cut into the final shapes—as dictated by customer specifications.

Global Success Through Saxon Precision

Over more than two decades, Smart Material has become known for unmatched quality. Its production is underpinned by rigorous quality management—from the warehouse to final delivery—ensuring every micrometer counts, enforced by microscopes, calipers, and high-precision electronic instruments.

Just a few flights of stairs above the workshops are the offices of Bill Esler and Dr. Andreas Schönecker. The exterior of their 1990s-era building may be modest, yet the penthouse-like attic office is strikingly modern—bathed in light, with a steel-and-glass aesthetic that feels both classic and contemporary. From here, Esler (an American) and Thomas Daue (based in Florida) steer the company’s future, rooted in Dresden. The location is strategic: close to Dresden’s renowned Fraunhofer IKTS, one of ten local Fraunhofer institutions, and Dr. Schönecker’s former workplace.

The offices here above Dresden’s rooftops reflect the vision that drives the company: transforming piezo ceramics’ unique potential into near-unthinkable products. The team’s collegial, even friendly, dynamic is a source of pride. While production staff conclude by early afternoon, the administrative team often works into the evening. And, at the break of each new day, the workshop doors open again two floors below, ready to start another day of pioneering work in smart materials.