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For 15 years now, researchers at the Dresden branch of the Fraunhofer IWU have been working on the additive technology LPBF (Laser Powder Bed Fusion), in which a laser beam melts metallic powder layer by layer locally at the points where the component grows. In this process, the entire physical and digital process chain must be mastered, to create a functioning component from powder. Adapted scanning strategies that define the sequence, length, alignment, and spacing of the laser paths are a promising approach for LPBF. They help to produce components that are more delicate, homogeneous, dimensionally accurate, and with improved surfaces.

At the new SEAM Research Center, researchers aim to unlock the potential of Screw Extrusion Additive Manufacturing (SEAM) even further. Its centerpiece is Epic3D, a newly developed portal printer that enables the production of large-format plastic components. The continuous deposition process and stiffening structures ensure durable parts, making the technology ideal for producing custom-designed facade elements and other weather-resistant products for the construction industry.

Wire or Fiber Encapsulating Additive Manufacturing (WEAM/FEAM) could significantly simplify the industrial production of components that require the integration of complex yet compact wiring, sensors, actuators, or lighting systems – by directly printing these components into the parts. The FEAM process uses glass fibers instead of wires, which are coated with a polymer and applied to any substrate without affecting its optical properties. This technology enables the creation of customizable lighting elements, sensors, or data conductors on 2D or 3D surfaces. A new development at Fraunhofer IWU: the Automated Cable Assembly (AuCA). Conventional robotics fails to produce and automatically lay flexible cable bundles in vehicles; AuCA, however, manufactures the wiring using a robot-guided way on a component and fixes it with a polymer.

The drive system of a rail vehicle is the largest energy consumer in operation, followed by the systems for temperature management of the passenger compartment and the drive system—regardless of the type of train propulsion. Batteries or fuel cells must be maintained at an optimal operating temperature in electrically powered trains without energy supply via overhead lines or third rails. Many rail operators are considering such trains for the nearly 40 percent of non-electrified tracks in Germany. The overall energy consumption in these trains significantly impacts range and potential operating times.

A book of success stories that inspires young women to take up mathematics, computer science, natural sciences and technology (STEM) with examples from science? That alone would not be enough for the Fraunhofer researchers Manja Mai-Ly Pfaff-Kastner, Esther Packullat, Dr. Isabel Michel, Lisa Martha Kunkel and Prof. Dr. Tanja Manuela Kneiske. »Forscherinnen im Fokus – Wir schaffen Veränderung« (Female Researchers in Focus – We Are Creating Change) wants more: to look at the world of artificial intelligence and simulation through the eyes of extraordinary female scientists and tell exciting, very personal stories in the process. ›Frau N. Hofer‹, as it is known for short, traces a variety of (life) paths in science and, in doing so, »incidentally« draws attention to fascinating opportunities for shaping the future, particularly in applied research.

EmulDan stands for ‘Energy Efficiency in Production through Multivalent Data Usage.’ In this joint project, the Fraunhofer IWU and its industry partners demonstrated that significantly lower consumption process routes are achievable while maintaining component quality, leading even to shorter processing times in some cases. Moreover, when process design is consistently energy-efficient, maintenance efforts for production equipment also decrease. EmulDan focuses on how to collect data, providing valuable insights for both AI-based models and improved manual control options.

More charging power, higher range, lower environmental impact: In the COOLBat joint research project, researchers from the Fraunhofer Institute for Machine Tools and Forming Technology IWU have teamed up with partners to develop next-generation battery enclosures for electric vehicles. The objective is to make the enclosures, a central component in any electric vehicle, lighter and cut the carbon dioxide emitted to manufacture them by 15 percent. The project partners aim to achieve this by combining individual systems, packing more functions into a smaller installation space, and using new heat-conductive materials and bio-based flame retardant coatings.

To ensure that food proteins do not become scarce in the future despite extreme weather conditions and increasing environmental stress, six Fraunhofer Institutes are focusing on indoor farming systems in the lighthouse project "FutureProteins" (alternative protein sources). How can wheatgrass, alfalfa, and potatoes be successfully grown indoors without soil, using only artificial lighting? And are these methods not only ecologically sustainable but also economically viable? Fraunhofer IWU is focused on this aspect, as the price tag is crucial for accepting product innovations in the food sector. In regions with significant poverty, high prices could make such products inaccessible.

Eliminating damages in offshore wind turbines is very expensive. When turbines are idle due to defective transmissions, repairs often require special cranes – high waves, strong winds, and poor visibility can hinder the deployment teams and further extend downtime. In the GEARFORM project, Fraunhofer IWU and its industry partners developed a hot rolling process to manufacture durable, large-module gears. In contrast to hobbing, hot rolling also boasts an outstanding material utilization rate and significantly shorter production times.

Sustainable value creation, which does not require limitations and conserves scarce resources of our planet, is likely the most urgent task of the 21st century. On the path to a circular economy, step-by-step optimizations will still be necessary. However, without groundbreaking innovations, the pace would be inadequate. Biomanufacturing, a still young discipline that integrates knowledge and methods from production engineering, biotechnology, and biology, is a promising approach: for example, it combines biotechnological processes with the capabilities of Industry 4.0 to substitute fossil materials and produce them in large quantities.