Electrification

Electrification is transforming industry, mobility, and heat supply. It spans the entire spectrum from energy generation to grids and storage, all the way to electrical consumers in machines, equipment, vehicles, and buildings. For electrical systems to contribute to decarbonization, applications, drives, power electronics, storage systems, and charging infrastructure must be efficient, robust, and scalable. Fraunhofer IFAM combines expertise in materials, processes, and systems – from powder to component, from prototype to application.

Only electrification powered by renewable energy can enable independence from fossil fuels in the medium term. At the same time, manufacturers face the challenge of maximizing efficiency, reducing costs, and building resilient supply chains. Solutions must therefore be material-appropriate, manufacturable, and system-integrated.

Our Services:

• Electric Drive Technology: Design, prototyping, test benches for electric motors up to 100 kW; cast coils, hybrid rotors, innovative cooling systems
• Soft Magnetic Materials: SMC composites, nanocrystalline cores, additively manufactured electrical steel sheets for loss reduction
• Thermal management: Gap fillers, thermally conductive adhesives, plasma protective coatings (DC and AC plasma), and ceramic-plasma-polymer insulation systems for power electronics and cooling circuits with high temperature and long-term stability
• Batteries & Manufacturing: Li-ion, solid-state, sodium/zinc systems; printed electrodes, BATTERIE digital®
• Charging Infrastructure: Design, grid simulation, techno-economic concepts, development of energy management systems; technical integration and operation of charging systems (including bidirectional), waste heat utilization

We increase efficiency and power density through innovative materials and manufacturing processes: Cast coils with integrated cooling channels achieve current densities exceeding 50 A/mm². Test benches ranging from <3 kW to 100 kW validate functionality and sensitivities at an early stage. Soft magnetic SMC cores and nanocrystalline compacts reduce losses at high frequencies.

For sophisticated cooling concepts, we also develop electrically insulating coating systems for cooling circuits, for example for use with ammonia as a cooling medium. A patented system combines ceramic oxide layers (anodized aluminum) on aluminum with additional plasma-deposited layers, thereby achieving robust electrical insulation within the cooling circuit. Aluminum is particularly suitable for this purpose, as it is corrosion-resistant to ammonia.

In addition, we are conducting research on novel paint-based electrical insulation coatings, such as specially filled systems with increased resistance to thermal, electrical, and chemical stress for applications in electric machines and power electronics.

From lithium-ion and solid-state cells to resource-efficient sodium/zinc systems: We integrate materials development with manufacturing processes and digital diagnostics. Additive manufacturing and printed electrodes open up new design possibilities. BATTERIE digital® uses data-driven forecasting to predict the condition and lifespan of batteries, ensuring safe, cost-effective, and sustainable systems.

We simulate expansion scenarios through 2030/2050, conduct techno-economic assessments of sites, and identify measures to reduce emissions. Our analyses take into account grid load, operational concepts, and legal frameworks – serving as a basis for investment decisions by municipalities and operators. In addition, we test new charging concepts and technologies, particularly with regard to new business models.

From materials to systems: We cover the entire value chain – material development, prototyping, test benches, and scaling. This also includes innovative electrical insulation coatings, such as highly durable, specially filled coating systems with enhanced resistance to thermal, electrical, and chemical stress.

Our customers benefit from near-production technologies, reduced development risks, and proven performance improvements. Whether electric motors, batteries, or charging infrastructure – we make electrification industrially feasible.