Magazine

MORE SUSTAINABILITY IN ELECTROMOBILITY THROUGH APPLICATION OF NEW METHODS TO IMPROVE BATTERY SERVICE LIFE | In the Fraunhofer Attract project "ProLIBs: A Battery Cell ID Card", the service life of batteries for electric vehicles and other applications is predicted and improved. The new method for lifetime prediction is based on a combination of measurements of battery properties and models of battery cell behavior. These measurements can be made directly while a battery is in use, for example, in an electric car. By applying this method for more accurate lifetime prediction of high energy lithium ion battery cells and other cell types such as solid-state batteries in the battery management system (BMS), it is possible to achieve increased lifetime with optimal charge and discharge profiles.

The aim of the Rapid-KI project is to develop control concepts for the local decoating of encapsulated or protective-coated electronic components. For this purpose, sensor data are collected, evaluated by means of AI and used for a highly dynamic real-time control of the laser processes in order to enable innovative recycling and repair concepts. The high flexibility and scalability of the laser technology also allows subsequent transferability of the development to a wide variety of application fields, e.g. decoating in the wind energy sector, ship, rail and aircraft construction as well as repair applications in the field of e-mobility.

DEVELOPMENT OF SODIUM-ION BATTERIES USING ADDITIVE MANUFACTURING | In the project “3DPrintBatt”, Fraunhofer IFAM and partners from industry and research are transferring 3D printing of sodium-ion batteries for electromobility and other applications to pilot production. The experts are combining battery expertise with know-how in Additive Manufacturing.

FUNCTION INTEGRATION IN FIBER-REINFORCED PLASTICS | At Fraunhofer IFAM, functional printing technologies can be used to functionalize various aircraft parts and components. Printed conductors and sensors for temperature, strain or impact measurement as well as heating structures can be incorporated into fiber-reinforced plastics for the aerospace sector.

PROTECTION OF FASTENERS IN AIRCRAFT CONSTRUCTION | In the collaborative project "InBe-KoVer", which was successfully completed in 2021, Fraunhofer IFAM, Ingenieurbüro Tank GmbH, and other partners worked on a local pretreatment and sealing of fasteners for the aging protection of CFRP metal structures and safety-relevant contacts in aircraft construction. The aim was to contribute to quality-assured, automated, and environmentally friendly aerospace manufacturing and repair. Fraunhofer IFAM has been involved in researching and improving the treatment and sealing homogeneity on different fasteners.

POWDER TECHNOLOGY AS A SUSTAINABLE ALTERNATIVE TO CONVENTIONAL MANUFACTURING PROCESSES | Scarcity of raw materials and increasing environmental pollution pose major challenges to today's world. This makes the sustainable, resource-saving manufacture of products all the more important. The entire product life cycle must be considered: From design through manufacturing and logistics to recycling. Powder technology offers the best prerequisites here. It allows material and energy consumption to be significantly reduced and raw materials to be easily recycled. Fraunhofer IFAM has been working on various processes of powder technology for many years.

Kidney stones are painful and can be life-threatening. They are shattered with a laser and the fragments are then removed with a grasper. If the fragments are too small, they cannot be grabbed and remain in the kidney, leading to the formation of a new kidney stone. Purenum GmbH, a spin-off from Fraunhofer IFAM, has developed a medical hydrogel to market maturity aimed at tackling this issue.

HOW TO AVOID GALVANIC CORROSION? | Galvanic corrosion, also called bimetallic corrosion or dissimilar metal corrosion is not a new phenomenon: Even in ancient times, it was found that copper nails used to fasten lead sheets to ship hulls corroded more quickly. Although this phenomenon has been known for centuries, this form of corrosion continues to cause damage and accidents. The experts at Fraunhofer IFAM can support in risk assessment and the selection of protection methods.

ARC-PROOF DC CONNECTOR SYSTEMS FOR HIGH-VOLTAGE APPLICATIONS IN BUILDINGS | In a world where practically all consumers require direct current (DC), DC networks offer immense advantages. Modern semiconductor technologies enable safe utilization, which is accompanied by the advantages of increased efficiency at lower costs. Fraunhofer IFAM has developed a concept for a very compact plug-in system that can transmit high DC power and ensure the required safety through the use of electronics and software.

THERMALLY CONDUCTIVE HEAT SINK MATERIAL FOR 3D PRINTING AND FUNCTION INTEGRATION OF ELECTRONICS | The integration of electronics or LEDs in additively manufactured plastic components involves heat dissipation during operation. Using 3D printing (Fused Filament Fabrication, FFF), thermally conductive plastic composites can be used as heat sinks. The material and process development for applications in the automotive and lighting sectors was part of the »Hyb-Man – Hybrid 3D Manufacturing of Smart Systems« project.