Newsroom / Press

Since 2025, Fraunhofer IWU has been heading the Lightweight Design Research Field. This alliance brings together the expertise of 16 Fraunhofer institutes, creating a powerful, interdisciplinary platform along the entire lightweight engineering value chain—from material development to validated application in products. The goal is to provide companies with integrated research and development services “from a single source” and to transform innovations into industrial applications.

Pultrusion is a fully automated manufacturing process in which fibers are guided through a resin bath and then pulled as an impregnated material through a heated die. In the cured state, the result is a profile that shows exceptionally high mechanical strength. Profiles can be pulled directly into the desired geometry and produced with virtually any wall thickness, including hollow chambers or undercuts if required. By combining different fibers and resin systems, specific properties can be precisely tailored. High production speeds, low manufacturing costs, and consistently high quality make pultruded profiles attractive for entirely new applications – for example, in solar systems, wind turbine rotor blades, or electric vehicle batteries. In reinforced concrete structures, these profiles far exceed corrosion-prone steel as reinforcement material.

Until now, fine particulate matter generated by tire and brake wear has not been addressed in European emissions legislation. Only with the introduction of the Euro 7 standard – taking effect at the end of 2026 for newly developed (type-approved) vehicles and at the end of 2027 for all newly registered passenger cars and light commercial vehicles – will binding limit values be introduced. The goal is to restrict the emission of fine particulate matter with diameters less than 10 micrometers, particles that can penetrate deep into the respiratory tract and are considered particularly harmful to human health. A project consortium involving Fraunhofer IWU has now introduced a stainless-steel brake disc that easily meets the strict EU requirements.

Wind turbines are typically designed for about 20 years of service, with a maximum of 30 years before replacement. Since the early 2000s, Europe has accumulated several tens of thousands of tons of composite wind turbine waste yearly. Decommissioned glass fiber – reinforced rotor blades are especially problematic: current disposal options like thermal recovery or minor reuse in cement are unsustainable, and EU regulations rightfully prohibit landfilling. Thus, end-of-life management is a key challenge for a circular economy in wind energy. For future wind turbines, Fraunhofer IWU, together with partners in the EU-funded RECREATE project, is demonstrating new approaches to material selection, joining technologies, and design. The goal is to enable wear-prone components to be replaced and to manufacture them from recyclable materials.

The Fraunhofer Competence Field Additive Manufacturing (Fraunhofer ADDITIV) will be represented at rapid.tech 3D with a diverse program and is actively shaping the content. With a combination of presentations “powered by Fraunhofer ADDITIV,” interactive expert tables, and the new continuing education format of short courses, it offers numerous points of interest for industry professionals and users.

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.

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.

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.

Rattling, clicking, and high-frequency vibrations not only compromise comfort; 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 investigations. 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.