Reference projects

Process parameters and processes for the manufacture of gears with lightweight structures, optimized surfaces in the root area, and printed, locally adapted carbon distributions (in-situ carburization with variable CHD) - Characteristic values for the tooth flank and tooth root load-carrying capacity of optimized, additively manufactured (PBF-LB/M) gears made of 16MnCr5 - Qualitative and quantitative influence of optimizations (lightweight design, surface, and adapted, localized carbon distribution (variable CHD)) on gear load-carrying capacity.

Due to the increased product variance in manufacturing companies as a result of the advancing individualisation of customer wishes, the number of necessary tool changes is increasing, which is accompanied by downtimes due to a lack of tool supply. By automating tool supply using mobile assistance robotics, solutions are to be found within the scope of the "AutoWerk" project to avoid interruptions in production and thus increase the economic efficiency of manufacturing.

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.

»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.

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.

This project develops a bio-based polyurethane reinforcement lamella reinforced with cellulose fibers to strengthen timber beams in sustainable construction. At Fraunhofer IGCV, reactive pultrusion processes are developed, including a flexible injection chamber design, to manufacture and validate pultruded demonstrator profiles made from bio-based polyurethane and natural fibers.

Factory planning is becoming increasingly short-cycle, and digital factory models offer the opportunity to increase the efficiency of factory planning. These factory models are usually based on point clouds, which are remodeled manually. SMEs can only afford this manual effort to a limited extent and therefore do not benefit from the advantages of digital models. This is where the “DigiFab4KMU” project comes in.

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.