The use of mechatronics enables production systems to be flexible and efficient at the same time. New possibilities are opening up, particularly in relation to combinations using lightweight components. Additive production processes mean additional leeway for designers regarding geometry and material.

Mechatronics is an inter-disciplinary field of activity related to mechanical engineering, electrical engineering and computer engineering. Sensors are integrated into production systems so as to record the current status of process and machine. The data is matched with open and closed loop control models; the optimum operating status is ultimately set by actuators. This means that a high level of efficiency can be guaranteed, even taking into account variations in process and environmental conditions. A pre-requisite for this is that the design of mechanical components, drives and open and closed loop electronics is coordinated down to the last detail.

Adaptronics transforms the system methodology of mechatronics, targeting a high degree of functional compression through the integration of sensors and actuators in the material level. This calls for the use of composites such as, for example, piezoceramics, shape memory alloys or active polymers with construction materials such as steel, aluminum or fiber plastic composites. The intentions are active components for machines and motor vehicles that will prevent faults such as distortions, vibrations or acoustic emissions at the point of onset. These measures are considerably more effective than pure design improvements and, since they are only active at the time and at the location of the fault, significantly more energy-efficient.

Focal points for research at Fraunhofer IWU into the development of mechatronic systems with greater resource efficiency are:

• Domain overlapping, linked simulation for integrated design of mechatronic components
• Development and prototypical implementation of mechatronic and adaptronic components for machine and motor vehicle construction and medical technology
• Use of material- and design potential for efficient lightweight design, in particular using metal foam, metal fiber plastic composites and active structural components with integrated sensors and actuators
• Employment of additive manufacturing technologies in component design
• Metrological analysis of existing systems, in particular to include sound radiation, for identification of weak points
• Implementation of methods to reduce sound radiation
• Design and implementation of high-performance actuators based on piezoceramics and shape memory alloys
• Development and realization of electronics for data capture as well as for transmitting energy and information