The starting point for the development project was a 2D sketch of a linear structural component to be installed in an e-vehicle at two different locations and functions. The pultrusion process had been selected as the manufacturing process. The load cases of the component were known as a further framework condition.
In close coordination with both industrial partners, the work included the design of the laminate structure, the selection of a suitable fiber-matrix system with special consideration of suitable multiaxial glass-carbon fiber textiles. The materials were qualified by upstream pultrusion tests. The multi-cavity pultrusion mold with associated closed injection and impregnation chamber was developed and manufactured by KraussMaffei. A particular challenge in the design of the pultrusion process was the guidance of the more than 800 carbon rovings and the numerous hybrid multiaxial textiles to the filigree hollow chamber structure of the profile.
After demonstration of TRL 5 on the IGCV pultrusion line, the entire process setup was transferred to a supplier in South Korea. The re-commissioning and training of the local staff was carried out by colleagues from C21. The mechanical performance of the pultruded components clearly exceed the requirements and are now in commercial series use at Hyundai.
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.
more infoDevelopment of innovative, large-scale technical process routes for different matrix systems for the production of FRP reinforcement bars with different bending radii and their implementation in semi-finished concrete products
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Rebar 3D creates innovative process routes for FRP reinforcement bars for the construction industry. Among other things, the focus is on developing a highly efficient, automatable bending process with intelligent thermal management to enable dimensionally accurate, durable, and resource-saving reinforcement solutions for concrete construction.
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Zero-emission aircraft present aviation with completely new development challenges. In the »AMoBaCoD« project, Fraunhofer IGCV and Fraunhofer IAPT are combining model-based design, production, and recycling processes into a comprehensive digital workflow. Semantic data models and automated AM design chains shorten development times and increase resource and cost efficiency.
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The aim of CU GreenCeramic is to create a fundamental database for the use of regenerative raw materials in the production of carbon fiber-reinforced plastics (CFRP) and carbon fiber-based ceramic matrix materials (CMC). To this end, alternative process routes for the production of carbon fibers and matrices based on regenerative materials are being considered. The aim is to establish, consolidate and expand the visibility and acceptance of the use of CFRP and CMC from renewable raw materials (regCFRP and regCMC) in society, industry and politics.
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Glass and carbon fibers are successfully used as reinforcement for plastic components. The innovative DRIFT technology allows the fibers to be embedded without the need for a separate carrier. This results in advantages such as short cycle times, high flexibility, efficient use of raw materials and gentle recycling.
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»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.
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Fraunhofer Institute for Casting, Composite and Processing Technology IGCV