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Surface pre-treatment, barrier layer, automated machining and assembly of cryogenic CFRP hydrogen tanks

© Fraunhofer IFAM
»HYTANK« – Contactless atmospheric-pressure plasma pre-treatment of a CFRP surface.

© Fraunhofer IFAM
»HYTANK« – Automated application of the barrier layer using a painting robot and a conventional automatic spray gun.

Technologietransfer für die industrielle Anwendung: Im Hintergrund die am Fraunhofer IFAM entwickelte flexible Fräskinematik, im Vordergrund die gemeinsam entwickelte Produktlösung von autonox Robotics. — © Fraunhofer IFAM
»HYTANK« – A milestone toward the future serial production of lightweight CFRP hydrogen tanks for aviation – a flexible, modular, automated assembly line (FFT Produktionssysteme GmbH & Co. KG).

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Fig. 1: “HYTANK” – Contactless atmospheric-pressure plasma pre-treatment of a CFRP surface.

Fig. 2: “HYTANK” – Automated application of the barrier layer using a painting robot and a conventional automatic spray gun.

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Fig. 3: “HYTANK” – A milestone toward the future serial production of lightweight CFRP hydrogen tanks for aviation – a flexible, modular, automated assembly line (FFT Produktionssysteme GmbH & Co. KG).

Christian Böhlmann and Dr.-Ing. Simon Kothe – New co-leadership heads Automation and Production Technology in Stade

© Fraunhofer IFAM
New Co-Leadership for Automation and Production Technology: Christian Böhlmann (left) and Dr.-Ing. Simon Kothe (right) are taking over the head of Fraunhofer IFAM in Stade from Dr. Dirk Niermann (center).

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New Co-Leadership for Automation and Production Technology: Christian Böhlmann (left) and Dr.-Ing. Simon Kothe (right) are taking over the head of Fraunhofer IFAM in Stade from Dr. Dirk Niermann (center).

Plasmatreat and Fraunhofer IFAM Collaborate on Rapid Industrial Implementation of PFAS-Free Coating Technologies

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Development of a magnetic carrier for pan coating with PLASLON^®

Hannover Messe 2026 – Automation, digitalization and robotics for the efficient, high-rate and versatile production of the future

© Fraunhofer IFAM
The newly developed flexible milling kinematics on a linear axis machines a CFRP vertical tail plane of an aircraft on a 1:1 scale with high precision.

© Fraunhofer IFAM/generated by KI
Research into bidirectional learning approaches for the acquisition of established manufacturing, joining and assembly technologies in human-robot collaboration.

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Fig. 1: The newly developed flexible milling kinematics on a linear axis machines a CFRP vertical tail plane of an aircraft on a 1:1 scale with high precision.

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Fig. 2: Research into bidirectional learning approaches for the acquisition of established manufacturing, joining and assembly technologies in human-robot collaboration.

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Fig. 3: In addition to the robotic end effector including vacuum suction blasting nozzle, the developed vacuum suction blasting system includes a removal control sensor for inline monitoring for quality assurance.

© Fraunhofer IFAM
Anodizing station with robust component holder, precise linear axis and robotics, equipped with a specialized anodizing end effector for targeted, high-precision surface treatments.

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Fig. 4: Anodizing station with robust component holder, precise linear axis and robotics, equipped with a specialized anodizing end effector for targeted, high-precision surface treatments.

Electrochemical Process Enables Recovery of Valuable Raw Materials

© Fraunhofer IFAM
Researchers at Fraunhofer IFAM are developing specialized electrodes that recover valuable metals such as lithium and cobalt from the process water accumulated during battery recycling.

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Researchers at Fraunhofer IFAM are developing specialized electrodes that recover valuable metals such as lithium and cobalt from the process water accumulated during battery recycling.

Major BMFTR Project for the Production of Sodium-Ion Battery Cells in Germany started

© UniverCell Holding Gmb
Pilot coating system for battery electrodes – the bridge between research and mass production.

© EDAG Group
3D visualization of a battery cell production line – complete process chain from electrode manufacturing to cell production.

Project Logo SIB:DE

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Fig. 1: Pilot coating system for battery electrodes – the bridge between research and mass production.

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Fig. 2: 3D visualization of a battery cell production line – complete process chain from electrode manufacturing to cell production.

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Fig. 3: SIB:DE project logo

Fraunhofer IFAM – Tolerance-conform adhesive bonding of fiber composite components and certifying training at JEC WORLD

© Fraunhofer IFAM
Fig. 1: Automated adhesive gap measurement and volumetric dosing with sensor-based real-time control on aircraft window frames using lightweight robots.

© Fraunhofer IFAM
Fig. 2: Automated dosing process for the gap-precise application of a paste adhesive material to a rudder hinge for tolerance compensation.

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Fig. 1: Automated adhesive gap measurement and volumetric dosing with sensor-based real-time control on aircraft window frames using lightweight robots.

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Fig. 2: Automated dosing process for the gap-precise application of a paste adhesive material to a rudder hinge for tolerance compensation.

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Fig. 3: Automated adhesive film application in an aircraft skin.

SAMSON – Towards the orchard of the future through digitalization, practical technologies and automated tools

© Project SAMSON
Figure 1: The tractor-mounted sensor box is equipped with precise sensors and camera systems. During normal journeys through the orchard, it records the individual data tree by tree.

© Project SAMSON
Figure 2: The alternance phenomenon illustrated on the “Red Prince” apple variety. Left: Three trees during flowering in 2023 – tree 2 (center) has almost no blossoms, tree 1 (left) and tree 3 (right) carry a lot of blossoms. Right: The same three trees during flowering in 2024 – tree 2 (center) is extremely rich in blossoms, trees 1 (left) and 3 (right) have almost no blossoms.

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Figure 1: The tractor-mounted sensor box is equipped with precise sensors and camera systems. During normal journeys through the orchard, it records the individual data tree by tree.

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Figure 2: The alternance phenomenon illustrated on the “Red Prince” apple variety. Left: Three trees during flowering in 2023 – tree 2 (center) has almost no blossoms, tree 1 (left) and tree 3 (right) carry a lot of blossoms. Right: The same three trees during flowering in 2024 – tree 2 (center) is extremely rich in blossoms, trees 1 (left) and 3 (right) have almost no blossoms.

© Project SAMSON

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Figure 3: Challenges in fruit tree cancer detection with AI. An AI model recognizes the fruit tree cancer site on a high-resolution smartphone macro image.

© Project SAMSON

© Project SAMSON
Figure 4: A further development of AurOrA enables targeted reduction of weeds between the fruit trees using a string trimmer.

© Project SAMSON
Figure 5: Insight into the “OrchardDigitizer” app. Left: Navigation menu. Center: Representation of the SAMSON B area with individual tree positions and color-coded flowering intensity (green = no flowers, white = many flowers). Right: Detailed view with number and percentage distribution of flowering intensities on the area.

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Figure 4: A further development of AurOrA enables targeted reduction of weeds between the fruit trees using a string trimmer.

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Figure 5: Insight into the “OrchardDigitizer” app. Left: Navigation menu. Center: Representation of the SAMSON B area with individual tree positions and color-coded flowering intensity (green = no flowers, white = many flowers). Right: Detailed view with number and percentage distribution of flowering intensities on the area.

© Project SAMSON

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Figure 6: Digital twin of a tree. Selecting a tree on the map (blue dot) opens the detail menu (example: tree no. 16 in row 1). In the “history” view, all digitally recorded measured values (e.g. flowering intensity, number of apples) are displayed in chronological order. The “details” view contains master data such as planting date, variety and species. In the “images” view, the historical images are stored for the respective measurement dates.

© Project SAMSON

New Machine Tool Robot (MTR) machines very precisely tempered steel, aluminum and fiber-reinforced plastic l EMO 2025

© Fraunhofer IFAM
The successful high-precision machining of a steel part shows that the machining robot on the linear axis is able to close the gap between industrial robots and machine tools.

© Fraunhofer IFAM
The newly developed flexible milling kinematics on a linear axis machines with high precision a CFRP vertical tail plane of an aircraft on a 1:1 scale at Fraunhofer IFAM in Stade.

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Figure 1: The successful high-precision machining of a steel part shows that the machining robot on the linear axis is able to close the gap between industrial robots and machine tools.

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Figure 2: The newly developed flexible milling kinematics on a linear axis machines with high precision a CFRP vertical tail plane of an aircraft on a 1:1 scale at Fraunhofer IFAM in Stade.

© Fraunhofer IFAM

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Figure 3: Technology transfer to industrial applications: In the background the flexible milling kinematics developed at Fraunhofer IFAM, in the foreground the jointly developed product solution from autonox Robotics.

© Fraunhofer IFAM

Real-Time Measuring Method Extends Lifespan and Enhances Safety of Batteries

© Fraunhofer IFAM
The graph shows how the impedance curves change dynamically during a charging cycle. The curves provide information on the physical and chemical processes taking place inside the battery cell.

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Lab setup for computer-assisted real-time measurement of impedance in a lithium-ion battery cell to analyze its state.

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The graph shows how the curves change dynamically during a charging cycle. The curves provide information on the physical and chemical processes taking place inside the battery cell.

© Fraunhofer IFAM

automatica 2025 – New type of machining robot closes the gap between classic industrial robots and machine tools

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Figure 1: The newly developed flexible milling kinematics on a linear axis machines a CFRP vertical tail plane of an aircraft on a 1:1 scale with high precision.

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Figure 2: The successful high-precision machining of a steel part shows that the machining robot on the linear axis is able to close the gap between industrial robots and machine tools.

© Fraunhofer IFAM

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Figure 3: Technology transfer to industrial applications: In the background the flexible milling kinematics developed at Fraunhofer IFAM, in the foreground the jointly developed product solution from autonox Robotics.

© Fraunhofer IFAM

High-performance elastomers and plasma polymer coatings to replace fluoropolymers in technical applications: new Fraunhofer project

In the future, a commercially available fluorine elastomer sealing ring could consist of a fluorine- free high-performance elastomer with adapted antioxidants, formulations and a specially developed coating.

© Fraunhofer IFAM
Kick-off: The Fraunhofer project team and the industry advisory board of "HATE-Fluor" at the first meeting on Tuesday, April 8, 2025. Photo: Fraunhofer IFAM.

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In the future, a commercially available fluorine elastomer sealing ring could consist of a fluorine- free high-performance elastomer with adapted antioxidants, formulations and a specially developed coating.

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Kick-off: The Fraunhofer project team and the industry advisory board of "HATE-Fluor" at the first meeting on Tuesday, April 8, 2025.

BMBF project launched for fast industrial implementation of sodium-ion technology

© Fraunhofer IFAM
Lab-scale precipitation reactor for the development of an active material for sodium-ion batteries.

© ZSW Ulm
Powder-Up! Pilot plant for the production of active materials for sodium-ion batteries.

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Lab-scale precipitation reactor for the development of an active material for sodium-ion batteries.

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Powder-Up! Pilot plant for the production of active materials for sodium-ion batteries.

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SIB:DE project logo

Quantum technology and AI: the key to safe second-life applications for lithium-ion batteries

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Spin-based quantum magnetic field sensor in a measuring process. The sensor is optically excited to start the magnetic field measurement. The information from the measured signal is encoded by the emission, forwarded and visualized in the form of magnetic field mappings.

JEC Composites Innovation Award 2025 for the Multi Functional Fuselage Demonstrator – MFFD

© JEC Composites/SEB_DHALLOY
York Roth (Airbus) is delighted to receive the JEC Composites Innovation Award 2025 together with Lars Larsen (DLR), Joost Koopman (GKN Fokker Aerospace) and Benjamin Diehl (Fraunhofer-Gesellschaft) on behalf of all MFFD project partners (f.l.t.r).

© Fraunhofer IFAM
The “MultiFAL” assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.

© Fraunhofer IFAM
The "MFFD" aircraft fuselage segment joined by thermoplastic welding at the Fraunhofer-Gesellschaft in Stade.

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Figure 1: York Roth (Airbus) is delighted to receive the JEC Composites Innovation Award 2025 together with Lars Larsen (DLR), Joost Koopman (GKN Fokker Aerospace) and Benjamin Diehl (Fraunhofer-Gesellschaft) on behalf of all MFFD project partners (f.l.t.r).

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Figure 2: Assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.

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Figure 3: The "MFFD" aircraft fuselage segment joined by thermoplastic welding at the Fraunhofer-Gesellschaft in Stade.

How To Replace PFAS in Medical Technology

Fluorine-free Hydrophobic Coating — © Fraunhofer IFAM
Many medical products require a hydrophobic coating to prevent cells from sticking or to optimize gliding and friction properties. Fraunhofer IFAM has developed fluorine-free coatings that mimic the previously usable properties of the fluoropolymers that were, as the hydrophobic coating on a nonwoven synthetic fabric shows.

Avoidance of the Adhesion of Dirt Particles to Silicone Surfaces — © Fraunhofer IFAM/Wolfgang Hielscher
Vacuum ultraviolet (VUV) modification of silicone surfaces is a possible substitute for gas-phase fluorination. The dirt-repelling, wear-resistant functional coating permits a wide range of applications in medical technology, from prostheses with an adjusted feel to dirt-repellent respiratory masks. The treated silicone hand (left) demonstrates how the coating prevents dirt particles from sticking to the surface.

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Figure 1: Many medical products require a hydrophobic coating to prevent cells from sticking or to optimize gliding and friction properties. Fraunhofer IFAM has developed fluorine-free coatings that mimic the previously usable properties of the fluoropolymers that were, as the hydrophobic coat-ing on a nonwoven synthetic fabric shows.

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Figure 2: Vacuum ultraviolet (VUV) modification of silicone surfaces is a possible substitute for gas-phase fluorination. The dirt-repelling, wear-resistant functional coating permits a wide range of applications in medical technology, from prostheses with an adjusted feel to dirt-repellent respiratory masks. The treated silicone hand (left) demonstrates how the coating prevents dirt particles from sticking to the surface.

© Fraunhofer IFAM / Wolfgang Hielscher

High-precision processing robot with innovative drive train – Made in Lower Saxony l Germany

Die neuentwickelte flexible Fräskinematik mit Hybridantrieb auf einer Linearachse bearbeitet hochpräzise ein CFK-Flugzeugseitenleitwerk im 1:1-Maßstab. — © Fraunhofer IFAM
The newly developed flexible milling kinematics with hybrid drive on a linear axis machines a CFRP vertical tail plane of an aircraft on a 1:1 scale with high precision.

© Fraunhofer IFAM
The successful high-precision machining of a steel part shows that the robot developed in-house with hybrid drive on the linear axis is able to close the gap between industrial robots and machine tools.

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Figure 1: The newly developed flexible milling kinematics with hybrid drive on a linear axis machines a CFRP vertical tail plane of an aircraft on a 1:1 scale with high precision.

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Figure 2: The successful high-precision machining of a steel part shows that the robot developed in-house with hybrid drive on the linear axis is able to close the gap between industrial robots and machine tools.

© Fraunhofer IFAM

Opening of the Offshore Drone Campus Cuxhaven – a milestone for drone research and offshore wind energy

Opening ODCC — © Fraunhofer IFAM
With numerous guests from business, politics and science, the new development and test environment for offshore drones was ceremoniously opened by Prof. Bernd Mayer, Director of Fraunhofer IFAM, and Marc Gerdes, Mayor of Cuxhaven, after a year of construction.

Area of the Offshore Drone Campus Cuxhaven — © Fraunhofer IFAM
Area of the development and test environment of the Offshore Drone Campus Cuxhaven.

© Fraunhofer IFAM
Fixed-wing drone S360MK.II at the opening ceremony of the Offshore Drone Campus Cuxhaven on the dike of the test site.

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Figure 1: With numerous guests from business, politics and science, the new development and test environment for offshore drones was ceremoniously opened by Prof. Bernd Mayer, Director of Fraunhofer IFAM, and Marc Gerdes, Mayor of Cuxhaven, after a year of construction.

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Figure 2: Area of the development and test environment of the Offshore Drone Campus Cuxhaven.

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Figure 3: Fixed-wing drone S360MK.II at the opening ceremony of the Offshore Drone Campus Cuxhaven on the dike of the test site.

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Figure 4: Inspection of the lightning protection system of a wind turbine in an offshore wind farm using a drone at a height of approx. 100 m. Risky work for people, such as this inspection, can increasingly be carried out with unmanned systems in the future.

From aviation to orthopedics: polymer patch made from dynamic polymer networks

The moldable, recyclable polymer patch can take on any desired shape and size.

Ultrathin, hard and sustainable non-stick coating revolutionizes shaping processes in injection molding and die casting

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UltraPLAS enables perfect reproduction of mirror-finish surfaces. Release-coated tool (l.) with injection-molded element.

New architecture for automated production of the world's largest thermoplastic aircraft fuselage demonstrated on a 1:1 scale

© Fraunhofer IFAM
Figure 2: The "MultiFAL" assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.

© Fraunhofer IFAM
Figure 3: Thermoplastic CFRP butt strap as connection of the two CFRP thermoplastic fuselage shells (on the left), joined by the CO2 laser welding end effector (right; project "BUSTI") in the "MultiFAL" assembly research platform.

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Figure 1: The "MFFD" aircraft fuselage segment joined by thermoplastic welding at the Fraunhofer-Gesellschaft in Stade

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Figure 2: The "MultiFAL" assembly research platform with inserted thermoplastic fuselage shells of the "MFFD" at the Fraunhofer-Gesellschaft in Stade. The yellow hexapod robots for holding and high-precision adjustment of the shape and position of the upper shell are clearly visible.

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Figure 3: Thermoplastic CFRP butt strap as connection of the two CFRP thermoplastic fuselage shells (on the left), joined by the CO₂ laser welding end effector (right; project "BUSTI") in the "MultiFAL" assembly research platform.

© Airbus
Figure 7: Clean Sky 2 final meeting on March 14, 2024, in the White Atrium Building in Brussels, Belgium, with the reviewers, the Joint Undertaking and part of the international team that contributed to the "MFFD".

© Fraunhofer IFAM
Figure 8: Stacking the completely joined fuselage section on the specially developed lower shell holder, which is also designed for transporting the entire fuselage section.

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Figure 7: Clean Sky 2 final meeting on March 14, 2024, in the White Atrium Building in Brussels, Belgium, with the reviewers, the Joint Undertaking and part of the international team that contributed to the "MFFD".

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Figure 8: Stacking the completely joined fuselage section on the specially developed lower shell holder, which is also designed for transporting the entire fuselage section.

Farewell and thank you: Fraunhofer IFAM bids farewell to its long-standing institute director Matthias Busse on his retirement

© Fraunhofer IFAM
Prof. Dr.-Ing. Matthias Busse is retiring after 21 years as institute director at Fraunhofer IFAM.

© Fraunhofer IFAM
Prof. Dr.-Ing. Matthias Busse was bid farewell to his retirement by Prof. Dr. Bernd Mayer and Prof. Dr.-Ing. Thomas Weißgärber (from left to right). They will now jointly lead Fraunhofer IFAM into the future.

© Fraunhofer IFAM
Prof. Dr. Axel Müller-Groeling (left), Executive Board of the Fraunhofer-Gesellschaft e.V., presented Prof. Dr.-Ing. Matthias Busse (right) with the Fraunhofer Medal for his achievements at his retirement ceremony. The medal honors individuals who have rendered outstanding services to the Fraunhofer-Gesellschaft.

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Prof. Dr.-Ing. Matthias Busse is retiring after 21 years as institute director at Fraunhofer IFAM.

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Prof. Dr.-Ing. Matthias Busse was bid farewell to his retirement by Prof. Dr. Bernd Mayer and Prof. Dr.-Ing. Thomas Weißgärber (from left to right). They will now jointly lead Fraunhofer IFAM into the future.

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Prof. Dr. Axel Müller-Groeling (left), Executive Board of the Fraunhofer-Gesellschaft e.V., presented Prof. Dr.-Ing. Matthias Busse (right) with the Fraunhofer Medal for his achievements at his retirement ceremony. The medal honors individuals who have rendered outstanding services to the Fraunhofer-Gesellschaft.

Clean Sky 2 "MFFD": Ready for robots – Welding thermoplastic aircraft fuselage structures

© Fraunhofer IFAM
The "MFFD" assembly research platform with inserted thermoplastic fuselage shells at the Fraunhofer-Gesellschaft in Stade, Germany.

© Fraunhofer IFAM
The participants of the "MFFD" stakeholder event obtained information about the current results of the Clean Sky 2 project "Large Passenger Aircraft" and discussed them intensively.

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The "MFFD" assembly research platform with inserted thermoplastic fuselage shells at the Fraunhofer-Gesellschaft in Stade, Germany.

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The participants of the "MFFD" stakeholder event obtained information about the current results of the Clean Sky 2 project "Large Passenger Aircraft" and discussed them intensively.

First results of the "SAMSON" fruit-growing digitization project at the Federal Government's Digital Summit 2023 in Jena

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The “sensor box” developed by Fraunhofer IFAM in Stade as part of the “SAMSON” project for recording and processing data in orchards can be mounted on any tractor via the three-point mount. This multi-sensor system contains the sensor technology for capturing camera images and precise GPS signals.

Increased efficiency of rotor blade production for wind turbines using PeelPLAS® release film from Fraunhofer IFAM

© Fraunhofer IFAM
In the newly developed low-pressure plasma plant of Fraunhofer IFAM, a 2.1 m wide film half-tube is equipped with an ultra-thin plasma-polymeric release layer.

© Fraunhofer IFAM
The flexible vacuum stretch-formed PeelPLAS® release film fits like a second skin into the 18 m long rotor blade segment mold and enables release agent-free demolding of the large FRP component after production.

© Fraunhofer IFAM
Pre-treatment-free coatable demonstrator of a rotor blade shell segment – protected by the PeelPLAS® release film.

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In the newly developed low-pressure plasma plant of Fraunhofer IFAM, a 2.1 m wide film half-tube is equipped with an ultra-thin plasma-polymeric release layer.

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The flexible vacuum stretch-formed Peel^PLAS® release film fits like a second skin into the 18 m long rotor blade segment mold and enables release agent-free demolding of the large FRP component after production.

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Pre-treatment-free coatable demonstrator of a rotor blade shell segment – protected by the Peel^PLAS® release film.

Fluorine-free into the future - environmentally friendly non-stick coating replaces per- and polyfluorinated chemicals (PFAS) on everyday products

© Fraunhofer IFAM
Pan samples coated with fluorine-free PLASLON® technology.

© Fraunhofer IFAM
Low-pressure plasma system with easily exchangeable electrode systems, which also function as product carriers.

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Pan samples coated with fluorine-free PLASLON® technology.

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Low-pressure plasma system with easily exchangeable electrode systems, which also function as product carriers.

Sustainable zinc-ion batteries for the energy transition – research project aims for rapid industrial implementation

© Fraunhofer IFAM
Aufbau und Entwicklung von Materialien und Komponenten für eine nachhaltige Zink-Ionen Batteriezellfertigung.

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Design and development of materials and components for sustainable zinc-ion battery cell manufacturing.

Pyrolysis processes promise sustainable recycling of fiber composites from rotor blades

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Offshore wind farm.

Lightweight construction, automation and robotics from Stade for sustainable & efficient aircraft production at SIAE 2023

At the SIAE 202, explorable via VR glasses: The Clean Sky 2 fuselage of the future can be seen in the virtual aircraft hangar on the right, which is currently being set up at Fraunhofer in Stade on a 1:1 scale with project partners — © Fraunhofer
At the SIAE 2023, explorable via VR glasses: The Clean Sky 2 fuselage of the future can be seen in the virtual aircraft hangar on the right, which is currently being set up at Fraunhofer in Stade on a 1:1 scale with project partners.

© Fraunhofer
Aircraft fuselage of the future: The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) in detail. It is currently being realized by Fraunhofer at the Research Center CFK NORD in Stade on a 1:1 scale with project partners.

© Fraunhofer IFAM
Transfer of currently manually performed drilling processes at CFRP vertical tail planes to mobile Cobots.

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At the SIAE 2023, explorable via VR glasses: The Clean Sky 2 fuselage of the future can be seen in the virtual aircraft hangar on the right, which is currently being set up at Fraunhofer in Stade on a 1:1 scale with project partners.

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Aircraft fuselage of the future: The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) in detail. It is currently being realized by Fraunhofer at the Research Center CFK NORD in Stade on a 1:1 scale with project partners.

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Transfer of currently manually performed drilling processes at CFRP vertical tail planes to mobile Cobots.

© Fraunhofer IFAM
The positioning and drilling end effector developed by Fraunhofer IFAM in Stade during the automated positioning of a cleat on the integral frame.

© Fraunhofer IFAM
Automated rudder hinge assembly in aircraft tail planes – Automated on-demand shim application to compensate component tolerances: a lightweight robot guides a rudder hinge under the dispensing system for liquid shim application.

© Fraunhofer IFAM
The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is operated by virtually coupled AGV systems, transports the robustly held CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.

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The positioning and drilling end effector developed by Fraunhofer IFAM in Stade during the automated positioning of a cleat on the integral frame.

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Automated rudder hinge assembly in aircraft tail planes – Automated on-demand shim application to compensate component tolerances: a lightweight robot guides a rudder hinge under the dispensing system for liquid shim application.

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The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is operated by virtually coupled AGV systems, transports the robustly held CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.

Offshore test infrastructure in the North Sea enables application-oriented development of marine protective coatings

© Fraunhofer IFAM
Deployment of the underwater lander off the island of Helgoland

© openseamap
Locations of the test field for maritime technologies of Fraunhofer IFAM and "MarGate" AWI Center for Scientific Diving both near Helgoland

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Deployment of the underwater lander off the island of Helgoland

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Locations of the test field for maritime technologies of Fraunhofer IFAM and "MarGate" AWI Center for Scientific Diving both near Helgoland

JEC WORLD – Sustainable and efficient production through automation and robotics from Fraunhofer IFAM in Stade, Germany

© Fraunhofer
Flugzeugrumpf der Zukunft: Der Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) im Detail. Er wird aktuell von Fraunhofer im Forschungszentrum CFK NORD in Stade im 1:1 Maßstab mit Projektpartnern realisiert.

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Transfer of currently manually performed drilling processes at CFRP vertical tail planes to mobile Cobots.

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Aircraft fuselage of the future: The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) in detail. It is currently being realized at Fraunhofer at the Research Center CFK NORD in Stade on a 1:1 scale with project partners.

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The positioning and drilling end effector developed by Fraunhofer IFAM in Stade during the automated positioning of a cleat on the integral frame.

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Automated rudder hinge assembly in aircraft tail planes – Automated on-demand shim application to compensate component tolerances: a lightweight robot guides a rudder hinge under the dispensing system for liquid shim application.

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The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is operated by virtually coupled AGV systems, transports the robustly held CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.

Fraunhofer IFAM establishes "Offshore Drone Campus" as new location in Cuxhaven

Concept Offshore Drone Campus Cuxhaven — © Fraunhofer IFAM
Conceptual graphic of the Offshore Drone Campus Cuxhaven with test flight areas, reference structures and connected workshops as well as a direct offshore flight corridor

© Fraunhofer IFAM
UAS deployment for the inspection of an offshore wind turbine as part of the research project AIDA. Supported by the Federal Ministry for Economic Affairs and Climate Action on the basis of a decision by the German Bundestag, Grant: 03EE3057A.

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Conceptual graphic of the Offshore Drone Campus Cuxhaven with test flight areas, reference structures and connected workshops as well as a direct offshore flight corridor

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UAS deployment for the inspection of an offshore wind turbine as part of the research project AIDA. Supported by the Federal Ministry for Economic Affairs and Climate Action on the basis of a decision by the German Bundestag, Grant: 03EE3057A

More sustainability in electromobility and Co: With new measurement methods for a longer service life of battery cells

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By measuring the so-called dynamic impedance of the battery cells the state of the battery cells during charging can be determined directly

Fruit-growing digitization project SAMSON: Federal Minister Cem Özdemir hands over funding notification at the International Green Week

© Fraunhofer IFAM
Concept illustration of the fruit growing farm of the future in the Alte Land – digital networking, autonomous machines, and AI-based evaluation algorithms are being researched on the experimental field in the SAMSON project.

Start of the fruit-growing digitization project "SAMSON": Federal Minister Cem Özdemir hands over the funding notification to Alexander Kammann (hochschule 21), Christian Böhlmann (Fraunhofer IFAM), Prof. Dr. Tim Tiedemann (HAW Hamburg), Jiahua Wei (TU Hamburg), and Benjamin Schulze (Fraunhofer IFAM) (f.l.t.r.) — © BMEL/photothek
Start of the fruit-growing digitization project "SAMSON": Federal Minister Cem Özdemir hands over the funding notification to Alexander Kammann (hochschule 21), Christian Böhlmann (Fraunhofer IFAM), Prof. Dr. Tim Tiedemann (HAW Hamburg), Jiahua Wei (TU Hamburg), and Benjamin Schulze (Fraunhofer IFAM); (f.l.t.r.).

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Concept illustration of the fruit growing farm of the future in the Alte Land – digital networking, autonomous machines, and AI-based evaluation algorithms are being researched on the experimental field in the SAMSON project.

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Start of the fruit-growing digitization project "SAMSON": Federal Minister Cem Özdemir hands over the funding notification to Alexander Kammann (hochschule 21), Christian Böhlmann (Fraunhofer IFAM), Prof. Dr. Tim Tiedemann (HAW Hamburg), Jiahua Wei (TU Hamburg), and Benjamin Schulze (Fraunhofer IFAM); (f.l.t.r.).

Motek l Bondexpo l Efficient large-structure assembly: outsourcing & automation of adhesive tolerance compensation process

© Fraunhofer IFAM
Virtual model within a digital twin: outsourcing of the curing process to an automated shim station.

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Virtual model within a digital twin: outsourcing of the curing process to an automated shim station.

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Automated rudder hinge assembly in aircraft tail planes – Automated on-demand shim application to compensate component tolerances: a lightweight robot guides a rudder hinge under the dispensing system for liquid shim application.

InnoTrans 2022 – Automated machining and assembly of large lightweight structures for rail vehicle construction

© Fraunhofer IFAM
Large-scale structure assembly on a 1:1 scale in the 4500 m2 research hall with a height of 15 m at Fraunhofer IFAM in Stade, Germany.

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Large-scale structure assembly on a 1:1 scale in the 4500 m² research hall with a height of 15 m at Fraunhofer IFAM in Stade, Germany.

InnoTrans 2022 – Mobile cleaning and disinfection robot frees rail vehicles from dirt & pathogens

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Mobile cleaning and disinfection robot of Fraunhofer IFAM in Stade for public transport vehicles (here in the S-Bahn Hamburg; R&D project “MobDi”).

Materials by recipe: powder kit for more flexibility and material diversity in 3D printing

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Few basic materials lead to many material property combinations. Concept of the "LPBF powder kit" for 3D printing by laser beam.

ILA 2022 – Sustainable and efficient aircraft construction through automation and robotics from Fraunhofer IFAM in Stade

© Fraunhofer
At the ILA 2022, explorable via VR glasses: The Clean Sky 2 fuselage of the future can be seen in the virtual aircraft hangar on the right, which is currently being set up at Fraunhofer in Stade on a 1:1 scale with project partners.

© Fraunhofer
Aircraft fuselage of the future: The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) in detail. It is currently being realized at Fraunhofer at the Research Center CFK NORD in Stade on a 1:1 scale with project partners.

© Fraunhofer IFAM
The robot-guided 3D printing end-effector developed by Fraunhofer IFAM and project partner IVW at the demonstrator for the pre-assembly of thermoplastic CFRP integral frames.

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At the ILA 2022, explorable via VR glasses: The Clean Sky 2 fuselage of the future can be seen in the virtual aircraft hangar on the right, which is currently being set up at Fraunhofer in Stade on a 1:1 scale with project partners.

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Aircraft fuselage of the future: The Clean Sky 2 Multifunctional Fuselage Demonstrator (MFFD) in detail. It is currently being realized at Fraunhofer at the Research Center CFK NORD in Stade on a 1:1 scale with project partners.

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The robot-guided 3D printing end-effector developed by Fraunhofer IFAM and project partner IVW at the demonstrator for the pre-assembly of thermoplastic CFRP integral frames

© Fraunhofer IFAM
Automated rudder fork assembly in aircraft vertical stabilizers - Automated on-demand shim application to compensate for component tolerances.

© Fraunhofer IFAM
The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is navigating by virtually coupled AGV systems, transports the precisely positioned CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.

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Automated rudder fork assembly in aircraft vertical stabilizers - Automated on-demand shim application to compensate for component tolerances.

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The first station of the "UniFix" flow line: The newly developed mobile holding fixture, which is navigating by virtually coupled AGV systems, transports the precisely positioned CFRP vertical tail plane element into the camera arena, where the shape retention of the holding fixture is checked.

ILA 2022 – 3D printing for automated pre-assembly of thermoplastic CFRP integral frames

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The robot-guided 3D printing end-effector developed by Fraunhofer IFAM and project partner IVW at the demonstrator for the pre-assembly of thermoplastic CFRP integral frames.

Everything in flow – Efficiency-enhancing flow-line production of large CFRP components

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Automation solutions for aircraft construction: Pioneering mobile holding fixture for flexible clamping, alignment, and transport of components reduces the workload of production processes considerably.

Fully automated: New Center for Digitally Networked Surface and Coating Technology opened at Fraunhofer IFAM

© Fraunhofer IFAM
Use of inline hyperspectral cameras for reliable detection of paint buildup in the aerospace industry

© Fraunhofer IFAM
Laser paint stripping in combination with CO2 snow cleaning for selective decoating and cleaning of ablation products

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Use of inline hyperspectral cameras for reliable detection of paint buildup in the aerospace industry.

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Laser paint stripping in combination with CO2 snow cleaning for selective decoating and cleaning of ablation products.

View into the paint booth (back) and pretreatment booth (front) of the »Center for Networked Surface and Coating Technology«. — © Fraunhofer IFAM
View into the paint booth (back) and pretreatment booth (front) of the »Center for Networked Surface and Coating Technology«

© Fraunhofer IFAM
Plant control system of the »Center for Networked Surface and Coating Technology«

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View into the paint booth (back) and pretreatment booth (front) of the »Center for Networked Surface and Coating Technology«.

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Plant control system of the »Center for Networked Surface and Coating Technology«.

Process integrated component marking: point by point to better traceability

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Recognition of individual plastic parts using fluorescent markers

Disinfected with light: self-cleaning surfaces protect against the transmission of bacteria and viruses

© Fraunhofer IFAM
Production of copper-doped titanium dioxide photocatalysts intercalated in layered silicates in the laboratory at Fraunhofer IFAM.

© Fraunhofer IFAM
Copper-doped catalyst in layered silicates composite into filaments for the Fused Filament Fabrication (FFF) 3D printing process.

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Production of copper-doped titanium dioxide photocatalysts intercalated in layered silicates in the laboratory at Fraunhofer IFAM

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Copper-doped catalyst in layered silicates composite into filaments for the Fused Filament Fabrication (FFF) 3D printing process.

Fraunhofer-IFAM_ExOne_PR-01092021_picture-4 — © Fraunhofer IFAM
Parts produced by metal binder jetting before (left) and after (right) sintering.

Fraunhofer-IFAM_ExOne_PR-01092021_picture-5 — © Fraunhofer IFAM
With the new X1 25Pro from ExOne, Prof. Frank Petzoldt and his team want to investigate pilot and pre-series production of components using metal binder jetting.

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Parts produced by metal binder jetting before (left) and after (right) sintering.

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With the new X1 25Pro from ExOne, Prof. Frank Petzoldt and his team want to investigate pilot and pre-series production of components using metal binder jetting.

Clean Sky 2 – ACCLAIM: Efficient installation of lighter sidewalls and hand luggage compartments through automation

Der für das Projekt Clean Sky 2 – ACCLAIM in Stade entwickelte Flugzeugrumpf-Demonstrator im 1:1-Maßstab mit Plattform und Transportlift (linker Bildrand). — © Fraunhofer/Leander Brieskorn
The 1:1 scale aircraft fuselage demonstrator with platform and transport lift (left edge of image) developed for the Clean Sky 2 – ACCLAIM project in Stade.

Clean Sky 2 – ACCLAIM l Automatisierte Montage: Hochpräzise Positionierung eines leichten Handgepäckfachs (Hatrack) an die Flugzeugstruktur mittels neu entwickeltem Hatrack-Roboter im Flugzeugrumpf-Demonstrator. — © Fraunhofer/Dr. Dirk Niermann
Clean Sky 2 – ACCLAIM l Automated assembly: high-precision positioning of a lightweight hand luggage compartment (hatrack) to the aircraft structure using a newly developed hatrack robot in the aircraft fuselage demonstrator.

Clean Sky 2 – ACCLAIM l Die gewichtsparenden Handgepäckfächer und Kabinenseitenwände nach der automatisierten Montage im Flugzeugrumpf-Demonstrator. — © Fraunhofer/Miguel Vargas
Clean Sky 2 – ACCLAIM l The weight-saving luggage compartments and cabin sidewalls after automated assembly in the aircraft fuselage demonstrator.

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The 1:1 scale aircraft fuselage demonstrator with platform and transport lift (left edge of image) developed for the Clean Sky 2 – ACCLAIM project in Stade.

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Clean Sky 2 – ACCLAIM l Automated assembly: high-precision positioning of a lightweight hand luggage compartment (hatrack) to the aircraft structure using a newly developed hatrack robot in the aircraft fuselage demonstrator

© Fraunhofer/Dr. Dirk Niermann

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Clean Sky 2 – ACCLAIM l The weight-saving luggage compartments and cabin sidewalls after automated assembly in the aircraft fuselage demonstrator

Morten Voß receives award for best presentation at the International Conference on Structural Adhesive Bonding 2021

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Morten Voß receives award at the Structural Adhesive Bonding 2021 conference for presenting his research results on "Validation and numerical investigations of Curie-supported accelerated curing using inductive heating".

Fraunhofer IFAM spin-off receives CE Mark for medical device for effective removal of kidney stones

Das Kernteam der Purenum GmbH: Dr. Sebastian Stößlein, Manfred Peschka, Prof. Dr. Ingo Grunwald (v. l. n. r.) — © Purenum GmbH
The core team of Purenum GmbH: Dr. Sebastian Stößlein, Manfred Peschka, Prof. Ingo Grunwald (f. l. t. r.)

Greifen und Entfernen der in »mediNiK®« eingebetteten Nierensteinfragmente. Große Darstellung: Animation der eingebetteten Nierensteinfragmente. Kleine Darstellung im Kreis rechts oben: Sicht des operierenden Urologen durch die Kamera des Endoskops. — © Purenum GmbH
Gripping and removal of the kidney stone fragments embedded in "mediNiK®". Large illustration: Animation of the embedded kidney stone fragments. Small representation in the circle at the top right: View of the operating urologist through the camera of the endoscope.

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The core team of Purenum GmbH: Dr. Sebastian Stößlein, Manfred Peschka, Prof. Ingo Grunwald (f. l. t. r.)

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Gripping and removal of the kidney stone fragments embedded in "mediNiK®". Large illustration: Animation of the embedded kidney stone fragments. Small representation in the circle at the top right: View of the operating urologist through the camera of the endoscope

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Logo Purenum GmbH

Fire-resistant and bio-based fiber-reinforced composites for structural lightweight design in ships

Project logo GreenLight

© Fraunhofer IFAM
Starting materials for the development of fire-resistant and bio-based fiber composites for structural lightweight design in ships

© MEYER WERFT
Fire-resistant and bio-based fiber composites have great potential, especially for structural lightweight design in cruise ships

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Project logo GreenLight

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Starting materials for the development of fire-resistant and bio-based fiber composites for structural lightweight design in ships

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Fire-resistant and bio-based fiber composites have great potential, especially for structural lightweight design in cruise ships

Development of novel protective coatings to ensure the reliability of electronic components

© Fraunhofer IFAM
Design of a novel coating system to protect against corrosion and improve the durability of electronic components

© Fraunhofer IFAM
Coating of an electronic component to improve durability and functional safety

© Fraunhofer IFAM/Dirk Mahler
Selective nanocoating using atmospheric pressure plasma to protect electronic components from corrosion

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Design of a novel coating system to protect against corrosion and improve the durability of electronic components

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Coating of an electronic component to improve durability and functional safety

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Selective nanocoating using atmospheric pressure plasma to protect electronic components from corrosion

Intelligent robots for targeted combating of viruses and bacteria

Im Projekt MobDi werden Desinfektionsroboter sowohl für den Einsatz in Gebäuden als auch in Verkehrsmitteln entwickelt. — © Fraunhofer IPA/Foto: Rainer Bez and Fraunhofer IMW/Graphics: Stefanie Irrler
In the “MobDi” project, disinfection robots are being developed for use both in buildings (left side) and in public transport (right side).

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In the “MobDi” project, disinfection robots are being developed for use both in buildings (left side) and in public transport (right side).

Automated pre-assembly of CFRP integral frames for aircraft construction

© Fraunhofer IFAM
The automation environment developed by the experts for Automation and Production Technology at Fraunhofer IFAM with the portal and the connected positioning and drilling end effector as well as the frame elevation for automated positioning and drilling of the cleat on the integral frame.

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The positioning and drilling end effector developed by Fraunhofer IFAM in Stade during the automated positioning of a cleat on the integral frame.

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The automation environment developed by the experts for Automation and Production Technology at Fraunhofer IFAM with the portal and the connected positioning and drilling end effector as well as the frame elevation for automated positioning and drilling of the cleat on the integral frame.

Fraunhofer IFAM develops twofold infection protection for implants

© Fraunhofer IFAM
Hip stem demonstrator with hybrid coating along the shaft.

Electron micro-scope image of osteoblast-like cells (MG-63) on the hybrid coating. — © Fraunhofer IFAM
Electron micro-scope image of osteoblast-like cells (MG-63) on the hy-brid coating.

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Hip stem demonstrator with hybrid coating along the shaft.

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Electron microscope image of osteoblast-like cells (MG-63) on the hybrid coating.

Analysis system enables targeted investigation of antiviral surfaces for material developers

© Fraunhofer IFAM
Sample preparation for the evaluation of antiviral surfaces.

© Fraunhofer IFAM
Testing the effectiveness of antiviral surfaces by means of quantitative real-time PCR analysis (qPCR) at Fraunhofer IFAM.

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Sample preparation for the evaluation of antiviral surfaces.

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Testing the effectiveness of antiviral surfaces by means of quantitative real-time PCR analysis (qPCR) at Fraunhofer IFAM.

Modelling of statistical influences of microdefects for a reliable production of casting components

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By modelling the statistical influences of microdefects, local material characteristics can be calculated, weaknesses in a design can be identified and the production process can be optimized in a targeted manner.

Adhesive bonding technology supports circular economy and life cycle assessments - New study by Fraunhofer IFAM

© Fraunhofer IFAM
The study "Circular economy and adhesive bonding technology" by Fraunhofer IFAM describes the role of adhesive bonding technology in the context of the circular economy and classifies it in the political framework conditions from a global and European perspective.

© Fraunhofer IFAM
The study "Circular economy and adhesive bonding technology" by Fraunhofer IFAM describes the technological potential of adhesive bonding technology for a sustainable use of resources.

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The study "Circular economy and adhesive bonding technology" by Fraunhofer IFAM describes the role of adhesive bonding technology in the context of the circular economy and classifies it in the political framework conditions from a global and European perspective.

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The study "Circular economy and adhesive bonding technology" by Fraunhofer IFAM describes the technological potential of adhesive bonding technology for a sustainable use of resources.

ILA Goes Digital – Automation & Production Technology for Adaptable Aircraft Production

© Fraunhofer
Automated installation of aircraft cabin side walls – Clean Sky2 – ACCLAIM project

© Fraunhofer IFAM
Mobile robotic system from Fraunhofer IFAM l Stade for high-precision machining processes in aircraft construction – MBFast18 project

© Fraunhofer IFAM
Automated adhesive film application and stringer integration for aircraft construction from Fraunhofer IFAM l Stade – AutoGlare project

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Automated installation of aircraft cabin side walls – Clean Sky2 – ACCLAIM project

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Mobile robotic system from Fraunhofer IFAM l Stade for high-precision machining processes in aircraft construction – MBFast18 project

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Automated adhesive film application and stringer integration for aircraft construction from Fraunhofer IFAM l Stade – AutoGlare project

45 meters draught: Test Center for Maritime Technologies puts research area off Helgoland in the North Sea into operation

Dr. Hanno Schnars | Fraunhofer Institute for Manufacturing Technology anTest Center for Maritime Technologies puts research area off Helgoland in the North Sea into operation. — © Fraunhofer IFAM/Deichblick
Test Center for Maritime Technologies puts research area off Helgoland in the North Sea into operation.

© DFKI GmbH, Animation: Meltem Fischer
Underwater robotics in the test field for maritime technologies.

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Test Center for Maritime Technologies puts research area off Helgoland in the North Sea into operation.

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Underwater robotics in the test field for maritime technologies.

Die cast aluminum coils for efficient electric motors

© Fraunhofer IFAM
An aluminum coil produced using high-pressure die casting with seven windings and a conductor height of approx. 1.5 mm.

© Fraunhofer IFAM
Illustration of a coil arrangement within a pedelec motor with copper coils (top) and an identical motor with cast aluminum coils (bottom).

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An aluminum coil produced using high-pressure die casting with seven windings and a conductor height of approx. 1.5 mm.

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Illustration of a coil arrangement within a pedelec motor with copper coils (top) and an

identical motor with cast aluminum coils (bottom).

SAE International in the USA awards the Wright Brothers Medal to Fraunhofer IFAM researchers

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At the Aerotech Americas Congress 2019 in Charleston, South Carolina, USA, the President of SAE International Dr. h.c. Paul Mascarenas, B.Sc., (on the left) presented Dipl.-Ing. Christian Möller of Fraunhofer IFAM, Stade, Germany, with the Wright Brothers Medal on behalf of the team of authors.

Release agent-free: ReleasePLAS® technology replaces silicone coating in wax injection molding

© Fraunhofer IFAM
ReleasePLAS® technology: Release agent-free wax injection molding by using a plasma polymer release layer.

© Fraunhofer IFAM
Release agent-free sprayed wax part and cast aluminium coil.

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Release^PLAS® technology: Release agent-free wax injection molding by using a plasma polymer release layer

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Release agent-free sprayed wax part and cast aluminium coil

Analog and digital – Automated manufacture and machining of fiber reinforced plastics

© Fraunhofer IFAM
Virtual test run of the process chain for stringer integration into an aircraft fuselage by offline programming of the motion paths of the robots

© Fraunhofer IFAM
The end-effector that will be presented by Fraunhofer IFAM at JEC WORLD 2019 allows automated high-precision placement of adhesive film on, for example, aluminum sheets

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Virtual test run of the process chain for stringer integration into an aircraft fuselage by offline programming of the motion paths of the robots

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The end-effector that will be presented by Fraunhofer IFAM at JEC WORLD 2019 allows automated high-precision placement of adhesive film on, for example, aluminum sheets