Stefan Maier

About me

Stefan Maier

Master electroplater with a background in materials physics — now an AI diagnostician for plating shops

More than 20 years of hands-on work at the plating tank, a degree in materials physics on top of that, and experience building AI systems that actually get used in production. Here you will find my background and the documented milestones of my career.

From the plating tank to AI development

Stefan Maier in a chemical protective suit in the stripping department of a plating shop
2005Apprenticeship & master craftsman
surface finishing
Stefan Maier at the blackboard in front of quantum mechanics equations, University of Vienna
2016Physicist
MSc, University of Vienna
Portrait of Stefan Maier from his time as a process optimizer and Lean manager
2020Process optimization
& Lean Management
Portrait of Stefan Maier as founder of secure galvano ai
2025Founder
secure galvano ai

My career started where it smells of acid and gloves are mandatory: in the stripping department of a plating shop. I completed an apprenticeship as a surface finishing technician, later passed the master craftsman exam in surface finishing (Meisterprüfung), and spent 15 years working directly on plating lines — from running the line to process engineering. In total, that adds up to more than 20 years in the industry.

Stefan Maier in the early 2000s in the stripping department of a plating shop, wearing a chemical protective suit at the plating tank
Early 2000s, in the stripping department. Even back then I wanted the same thing: all process data in one place — instead of pulling records together from several sources to get to the bottom of a quality problem.

I know what it feels like when a bath goes off or a customer complaint comes in, and during root cause analysis you lose track of hundreds of individual readings. That experience went into the analysis logic: a prioritized list of recommended actions for each analysis run, which helps your team plan its work and spot deviations before they turn into scrap.

Alongside that, I studied physics at the University of Vienna (Universität Wien) — MSc in Environmental Physics with a focus on materials physics, grade average 1.1 (on the Austrian scale, where 1 is the best grade), graduated with distinction. My master's thesis on high-pressure torsion of high-entropy alloys taught me how to derive reproducible results from measurement data — a discipline that is rarely formalized in day-to-day production.

On top of that came Lean Management training as a methodical basis for structured root cause analysis. Shop-floor practice, physics and methodology work together in every analysis.

On June 1, 2025, I turned this into my own company — deliberately focused on a single industry rather than on digitalization in general.

Today I bring these three worlds together in AI systems for electroplating that run locally, deliver traceable results and can be followed in an intro call without any prior knowledge. I know both sides — running the line and analyzing the process data — and the methodology that connects them. Otherwise, an AI project in a factory needs several departments to work together, and that coordination is usually the bottleneck, not the technology. I can discuss an idea with the line operator at the line in the morning and walk production management through it as a working demo in the afternoon.

I don't work alone. You have one point of contact, and behind him are experienced specialists in law, tax, data security and cybersecurity, and intellectual property — the same people who supported the first project. Who contributed (in German) →

What drives me

Helping plating shops achieve more with fewer resources. The industry is under pressure — energy costs, chemical prices, ESG requirements, a shortage of skilled workers. AI is not an end in itself here; it is a tool that only pays off when it is used in the right place.

Practice before hype

Solutions have to work at the tank, not just in the demo. Usable on site, transferable to your own team, compliant with data protection rules.

Method before magic

Reproducible models, explainable decisions. Model audit by TÜV AUSTRIA Trusted AI (TRUSTIFAI) successfully completed.

Sustainability before growth

Fewer chemicals, less energy, less water, less scrap — as target metrics that are measured and documented in the project.

Credentials & Qualifications

Documented milestones from more than 20 years

From the apprenticeship certificate as a surface finishing technician, through the master craftsman exam, to the Master of Science in Environmental Physics (focus on materials physics, with distinction) — the formal diplomas, apprenticeship certificates and certificates, shown in the original. Click a card to open the document in full resolution.

Model Audit & Trusted AI

Inspection of the anomaly detection system under the TÜV AUSTRIA AI Inspection Framework (TRUSTIFAI) — with an audit interview and a live demonstration of the model. Excerpt from the management summary of the inspection report.

Academic Education

University of Vienna — master's program in physics with a focus on materials physics & environmental physics.

Electroplating & Surface Finishing

Apprenticeship certificate as a surface finishing technician (Lehrbrief) and master craftsman diploma (Meisterbrief), shown in the original.

Management & Methodology

Process management, IT service management, traditional and agile project management, value stream methodology.

Personal Development

Additional training — coaching, counseling psychology and personal development.

Press & Publications

Press coverage · August 6, 2026
“Engineer from Alberschwende develops inspection software that keeps getting better with AI”

Vorarlberger Nachrichten · VOL.AT — a profile of the AI-based inspection software for electroplating, the completed first pilot project, and the question of why individual readings in the green range can still lead to quality problems.

Article by Andreas Scalet, Vorarlberger Nachrichten — published on August 6, 2026, also on VOL.AT. WISTO also published the profile on wisto.at.
Read the profile (wisto.at, in German)
Published
Trustworthy AI in Electroplating

Trade journal Galvanotechnik — AI-based anomaly detection that is traceable and verifiable.

Trade article (PDF, German)
In preparation
Training apprentices in data analysis with AI

How skilled workers and apprentices learn to analyze process data themselves with modern AI tools — a field report, coming soon in Galvanotechnik.

Notify me when it is published

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