Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Shape Memory Alloys - SMA Production Engineering

Economical manufacturing as the key to successful products

Production engineering plays a particularly important role in the manufacture of SMA applications. As a production engineering institute, Fraunhofer IWU has extensive expertise and many years of experience in all important production technologies that are specially adapted to the unique properties of shape memory alloys. A central focus is also on the systematic analysis of economic efficiency and the development of methods for quality control in production.

Focus of our research

Fraunhofer IWU offers all technologies and processes for the production of SMA actuators and sensors. This includes established processes in the industry, such as crimping and SMA wire handling, as well as processes that have not yet been fully qualified, such as thermal joining technologies for SMA or additive manufacturing.

Our range of services

  • Process development for semi-finished product conditioning and component manufacturing, e.g. of SMA springs
  • Automated manufacturing processes for SMA wire actuator systems
  • Quality control methods
  • Development of joining technologies for SMA components: Crimping, welding, soldering
  • Additive manufacturing of SMA elements
  • Textile manufacturing processes for SMA wires
  • SMA polymer integration with thermoset or thermoplastic processes

Reference projects

 

Optimization of series production of SMA wire actuators using a modular automation platform

In this project, several partners are pooling their expertise to develop a modular automation platform that will enable SMEs to build on the collective know-how of the project and implement their own cost-effective automation solutions for the manufacture of SMA-based actuator systems.

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SMA semi-finished product conditioning

SMA are thermosensitive materials that change their geometry depending on the temperatures and further show elastic properties in certain temperature ranges. This effect, known as pseudoplasticity, is based on a reversible phase transformation and can be used as an actuator. Actuator wires and spring actuators are usually conditioned or pre-cycled to compensate the running-in behavior in the first load cycles, and ensure consistent material behavior. 

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Crimp development

The integration of wire actuators into fully automated production processes is technically challenging and has only been solved to a limited extent so far. We have developed a scalable crimping concept that is aimed at broad industrial applicability.

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Thermal joining processes for SMA

The reliable integration of SMA components is an essential task in the manufacture of SMA applications. Therefore, in addition to mechanical technologies for joining SMA, Fraunhofer IWU is also investigating thermal joining processes to make systems more reliable, flexible, and economical. 

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Additive manufacturing of SMA

Thermo-mechanical optimization of Ni-Ti-based shape memory elements often results in highly complex structures. For this reason, and due to the difficulties involved in using conventional forming processes, the use of additive manufacturing processes is particularly interesting and innovative in this area, as it allows for functional consolidation with maximum design freedom. 

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SMA polymer integration

The integration of SMA into polymer parts opens up a bunch of possibilities for making smart and adaptive components. Using injection molding, SMA elements can be embedded directly into the polymer matrix, which means complex actuator systems can be made in just one step. 

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