Newsroom / Press

Presses require a large footprint, and both operating and capital costs for machines and tooling are enormous. Is there really no alternative to a press when forming precision components? Martin Wagner, a specialist in metal forming machines, aims to prove otherwise with the smartROLL project. Together with the project partners, he is convinced that complex precision components – such as heat exchanger plates for data centers, cooling plates for electronics, or connector elements for the automotive industry – can in the future be formed using hollow embossing rolling at costs up to 70 percent lower, without any loss in quality.

Paper packaging offers a number of advantages over its plastic counterparts: It has a high recycling rate, lower CO₂ emissions, and lower disposal costs. However, it cannot yet be sealed without adhesives or layers of plastic—a disadvantage for manufacturing and recycling processes. In the PAPURE project, four Fraunhofer institutes are developing a laser-based process that enables completely dhesive-free paper packaging.

How can we achieve intelligent teamwork between humans and robots in production? The Fraunhofer NeurOSmart technology platform combines sensor technology with AI-supported data processing and energy-efficient chips that mimic the way the human brain works.

Rattling, clicking, and high-frequency vibrations not only compromise com-fort; they fundamentally define the perceived quality of a premium e-bike or high-performance cycle. To address this, Fraunhofer IWU and its development partner are offering e-bike manufacturers a joint testing and development program. At Fraunhofer IWU Dresden, a newly developed acoustic test rig housed in an anechoic chamber enables high-precision acoustic investiga-tions. This infrastructure allows e-bike manufacturers to bring their products to market maturity much faster.

On November 4, an Ariane 6 rocket successfully carried the Earth observation satellite Sentinel-1D into orbit. Looking ahead, the new launch vehicle is expected to lift off at short intervals, allowing Europe to remain a key player in space research. A perfectly synchronized production network that manufactures components with the highest precision is essential for aerospace applications. Sensors can play a crucial role here—from physical traceability of parts to condition monitoring and quality management. Advanced sensor technology also helps make energy consumption in production more manageable.

This year’s exhibits at Formnext focuse on materials particularly suited for aerospace applications but so far rarely used in LPBF (Laser Powder Bed Fusion) processes, as well as on printed components with integrated electrical functions. But the booth itself is also a highlight: It is fully 3D-printed, using elements made from biodegradable plastic and recyclable polypropylene (PP). After the event, the modular system will not be discarded. The high-quality exhibition furniture will be reassembled and repurposed for presentation purposes at Fraunhofer IWU.

Under the leadership of Fraunhofer IWU, 28 partners from academia and industry are working to reduce the carbon footprint of electric vehicles by at least 25 percent and significantly increase the share of recycled materials. After a year and a half, the European research project ZEvRA (Zero Emission electric Vehicles enabled by haRmonised circulArity) can already report positive interim results. Examples include vehicle roofs that can demonstrably be converted cost-effectively into new vehicle components, and many aluminum components can be nearly fully made from recycled (secondary) aluminum. Plastics and composite materials with up to 97 percent recycled content have already been processed into the first demonstration parts.

At Formnext 2025, the Fraunhofer IWU will present the latest generation of the WEAM tool (Wire Encapsulating Additive Manufacturing). This technology opens up entirely new possibilities: components can be manufactured with a wide range of integrated electrical functions, offering significantly better performance for sensing and load-bearing tasks compared to paste-, ink-, or powder-based printing methods. The key lies in the use of standard wires and cables, which, due to their homogeneous alloy and constant conductor cross-section, ensure perfect electrical properties.

Battery housings in electric vehicles must be impact-resistant, absorb crash energy, protect against short circuits, and be heat-resistant. Efficient heat dissipation is essential, but cells also need protection from excessive cooling. The housing must resist damage from stones and salt, fit the vehicle’s underbody, add rigidity, and, being lightweight, help increase range. Aluminum foam satisfies these requirements.

Additive manufacturing, particularly the Laser Powder Bed Fusion (LPBF) process, offers new possibilities in toolmaking due to its considerable design freedom. Fraunhofer IWU is unlocking this potential in two research projects, "AdTopoTool" and "EWAM." The goal is to accelerate the development and production of more efficient tools for sheet metal forming and injection molding. This also improves the quality of the components, which can be produced more efficiently using such tools.