FutureCarProduction | Lead project for the evaluation of new and sustainable car body concepts

The MIKADO project is concerned with the development of lightweight structures made of composite tubes and cast nodes. It aims to research and optimise innovative joining technologies to create lightweight yet strong structures for various application areas such as automotive and mechanical engineering.

The MonCoat project aims to develop an automatic online monitoring system for checking the mold coating condition, which minimizes the risk of deviations.

»Diggi Worms« is an innovative system developed to search and grip components. It is based on a novel technology and offers an efficient solution for the automated handling of components, for example for precise application in additive manufacturing.

The consortium of the lead project »FutureCarProduction« will develop holistic solution approaches for the evaluation of new car body concepts in the automotive industry. To this end, it is necessary to establish methods, processes and technologies with which ecological sustainability can be methodically evaluated and technologically guaranteed, always in conflict with technical performance and costs.

The casting process is a complex manufacturing process that depends on various influencing variables. In order to optimise the process, Fraunhofer IGCV and its partners are therefore researching sensor technology for foundry processes, methods for component tracking and AI models for foundry use.

A central challenge in the application of inorganics is the coring of filigree inner cores, as the inorganic binder does not thermally decompose during casting. The simulation model developed at Fraunhofer IGCV predicts the formation and expression of the core fracture in a virtual test laboratory.

The aim of the AnomalieAI project is to develop an approach using Artificial Intelligence (AI) to identify anomalies in castings in order to save both costs and time.

The CondMon3D project deals with the use of camera images from a process room camera inside a 3D printer to obtain measurement data for the expected component quality and to be able to readjust it during the process.

Indirect additive manufacturing offers the possibility of producing very complex geometries at moderate costs. It is important to note here: The more complex the mould, the more complex the subsequent cleaning process. Here, the Schichtbau² project offers a possible solution that also holds out the prospect of a fully automated process.

With increasing demands on the structural design and layout of modern components, research in the field of design and simulation is also becoming more and more important. This includes the development of CAE tools that can be used to create new simulation tools.