Fiber composites

Lightweight construction with fiber plastic composites

Developments in mechanical and plant engineering are essentially characterized by increasing requirements regarding productivity, component quality and reproducibility, while simultaneously saving energy and resources, thus achieving economic efficiency. These objectives can only be achieved to a limited extent when using conventional materials and construction methods. A conflict of objectives arises, for example, when productivity shall be increased and the dynamic behavior shall be improved at the same time. High dynamics of movement can only take place by mass reduction of the moved components, if the driving energy remains the same. However, lightweight constructions require detailed knowledge of applied loads and stresses occurring in the component. Especially when using fiber plastic composites (FPC), requirements on engineering are high. The direction-dependent properties of this material group must be considered in design and simulation. This is the only way that ideal characteristics can be set up and operational stability can be ensured.

The Fraunhofer IWU offers customized solutions not only for design and calculation, but also for construction, optimization and manufacturing of prototypes and small series. Moreover, we determine the mechanical properties of the prototypes by conducting experiments in order to support construction and performance capability.

  • Federal Cluster of Excellence MERGE: graded metal foam structures with plastic connections
  • Metal-plastic hybrid components
  • In-situ heating of organic sheets
  • CFRP cross beam
  • CFRP z-slider
  • Medical engineering: improved surgery

  • Cost-efficient differential design instead of integral design
  • Increasing economic efficiency of manufacturing processes
  • Design of resource-efficient fiber composite profiles
  • Forming of thermoplastic fiber composites
  • Recycling of FRP
  • Utilization of renewable plastic and fiber materials
  • Manufacturing strategies for efficient production of fiber composites (small to large series)
  • Utilization of renewable resources
  • Individualization of the pultrusion process
  • Development of connection systems adapted to loads

Development of process chains

  • Market analysis
  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Planning and technological dimensioning of processes, tools and machines

Development and evaluation of manufacturing and recycling strategies

  • Market analysis
  • Feasibility studies
  • Technology development
  • Development of characteristic process values and ideal manufacturing and recycling strategies
  • Benchmarking
  • Numerical simulation
  • Manufacturing of prototypes

Machine technology

  • Pultrusion plant for manufacturing straight and curved profiles
  • Hot press
  • Laying-up
  • Diverse infusion processes
  • Press technology for processing organic sheet metals, SMC etc.