Power Electronics

The production processes of power electronics, especially functional elements such as heaters or coils and power conductors like wiring harnesses, are a key technology for innovation and international competitiveness. Automation and quality assurance in production are essential to ensure consistently high quality and increased productivity.

With the increasing demand for smaller and more efficient devices, components must become more compact and powerful, requiring advanced manufacturing techniques and materials. Power electronics generate a lot of heat that must be effectively dissipated to ensure the reliability and longevity of the components. This poses special challenges for the materials used and the mechanical coupling to the carrier component. They must withstand high thermal and electrical loads, be resistant to aging, and be processed quickly and economically. At the same time, the product should be easily recyclable at the end of its lifecycle.

Fraunhofer IWU provides innovative technologies with its tools for the application, assembly, and contacting of electrically conductive materials, enabling the complete automation of wiring harnesses for the first time and setting new standards in productivity.

With the WEAM process, IWU is a technology leader in the field of wire integration and application. Through continuous development, the following additional technologies are also available to you.

Our technologies

 

WEAM - Wire Encapsulating Additive Manufacturing

 

AuCA - Automated Cable Assembly

Our Equipment

Projects

 

Printed sensors and wiring harnesses on vehicle door components

A fully printed control module for operating light elements, wiring with integrated printed force sensors, circuit traces for piezo elements and LEDs, as well as automated laying, insulating, and fixing of power conductor traces.

 

Individually Printed Actuator Coils

The WEAM process enables the construction of a theoretically unlimited number of coil windings through rotational decoupling. Thanks to the free choice of materials, we can fully automate the integration of coils into various environments. The additive component of the process allows for the creation of any coil contours to achieve targeted field line densities.

Other Reference Projects

in the area of Functionalization Technologies