PulFlex – PulBraiding and bending of thermoplastic fiber composites

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.

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.

Japan and Korea are among the world's leading nations in the development of composite materials and carbon fibers. MAI OSAKA connects European and Asian players to jointly shape technological trends and solutions for sustainability in the composite industry.

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.

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.

Fraunhofer IGCV advances Automated Fiber Placement for the A350-1000 door surround structures, moving from TRL 2 to take-off readiness. A milestone in aerospace manufacturing, delivering lightweight, precise door structures at scale.

Additive manufacturing processes have been in vogue for years - the production of individual one-offs and functionally optimised components in small series mean great progress, especially for mechanical and plant engineering, aerospace and the automotive industry. Fraunhofer IGCV has recognised this potential and has since been researching additive manufacturing processes for the production of mechatronic multi-material components.

In the successfully completed project "Qualification of additive manufacturing for process engineering pressure equipment (QuAFD)", material states and properties on (vessel) walls were investigated for the material 1.4404 (austenitic stainless steel) in the range of 1 - 5 mm thickness. Differences between the same manufacturing systems and build-up directions were shown and quantified. The following design rules and procedures for a safe design were derived

The Espresso research project is developing highly oriented thermoplastic tapes made from recycled carbon fibers for use in second-life structural components like bicycle handlebars.

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.