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.
»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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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.
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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.
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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.
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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.
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The project focuses on the ecologically sustainable design of structural construction methods and production technologies for future and existing helicopter structures.
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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.
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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.
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
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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Fraunhofer Institute for Casting, Composite and Processing Technology IGCV