Reference projects

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.

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.

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.

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.

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.

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.

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.