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.