Reference projects

»PulFlex« is developing a novel process chain for curved, continuous fiber-reinforced thermoplastic profiles. The aim is to create a lightweight, durable, and fully recyclable cross-member made of glass fiber-reinforced plastic for high-voltage power lines—achieved by combining PulBraiding and bending processes.

HEMERA serves to optimize manufacturing processes for CFRP fuselage structures. Innovative manufacturing processes, stringer-reinforced designs, and preparation for high-rate production make the processes fit for the aircraft of the future—lighter, faster, more efficient. Lightweight construction and series production readiness go hand in hand.

The HERA project is looking at new manufacturing technologies for CFRP fuselage structures. The goal is to create automated processes that also enable high production rates and make the structures lighter and more sustainable. From small components to large structures, tools and processes are being tested, validated, and checked for efficiency and resilience.

In the DiBattma-pro research project, an application-oriented, partially automated production line for polymer solid-state cells with a digital twin is being set up.

Artificial intelligence promises enormous efficiency gains in aircraft production—but without certifiability, its potential remains untapped. In the TrustME project, Fraunhofer IFAM and Fraunhofer IGCV are working with partners to develop trustworthy AI for quality prediction, image processing, and flexible production planning, and are creating methods for its approval in aviation.

In the MaTCH research project, Fraunhofer IGCV is developing a thermoplastic pultrusion process for manufacturing continuous fiber-reinforced composite pipes for hydrogen transport. The focus is on the reliable implementation of thermoplastic braiding and winding pultrusion for continuous, recyclable production.

In the RAILS research project, Fraunhofer IGCV is developing a thermoplastic pultrusion process based on recycled materials. The aim is to produce sustainable lightweight composite structures for rail transport that combine high mechanical performance with resource efficiency and recyclability.

NATUR addresses lightweight construction methods and technologies for CFRP fuselage structures that contribute to reducing the global warming potential (GWP) along the entire process chain through the consistent use of material residues, recycled carbon fibers (rCF) and out-of-autoclave (OoA) prepregs, as well as associated energy-reduced production processes and systems. The focus is therefore on optimizing component design and production planning for a sustainable material cycle, as well as energy- and emission-optimized production control. The weight reduction also makes a significant contribution to reducing the environmental impact during the aircraft's service life.

The project focuses on the ecologically sustainable design of structural construction methods and production technologies for future and existing helicopter structures.

The fibre-matrix adhesion (FMH) represents an important core variable in composite technology. In order to optimise it, it must be measured and evaluated. The WiPull project aims to determine procedures for the correct testing of the respective fibre-matrix combinations and uses analysis data from micromechanical pull-out tests for this purpose.