Magazine

The ODCC — Offshore Drone Campus Cuxhaven — is a location for the joint application-oriented development and testing of offshore UAS (Unmanned Aircraft Systems) and their operational concepts. The focus of Fraunhofer IFAM is on questions of maintenance and inspection, as well as monitoring of important maritime structures including regulatory framework conditions.

CHARGING MANAGEMENT FOR ELECTRIC VEHICLE FLEETS - SOLVER-BASED, CUSTOMIZED AND COST-EFFICIENT | The experts in the "Research Data" unit at Fraunhofer IFAM use a specifically developed simulation environment to determine the most cost-effective solutions for operating electric fleets on site for individual scenarios.

ELECTRIC CARS AS ROLLING CHARGING STATIONS: In the "ROLLEN" research project, Fraunhofer IFAM and its partners have shown how electric vehicles with bi-directional charging technology can store surplus energy from photovoltaic systems and pass it on in a targeted manner - to buildings, other electric vehicles or even to the public power grid.

ELECTROCHEMICAL RECOVERY OF CRITICAL RAW MATERIALS FROM WASTEWATER | The efficient recovery of critical raw materials from batteries and production waste is a major challenge for the modern battery industry. In the MeGaBat project, we are developing a sustainable, cost-effective, and low-emission technology for the electrochemical recovery of lithium, cobalt, and other critical raw materials from aqueous sources (wastewater) to solid production waste. Our goal: to establish a flexible, scalable process that advances the circular economy in the battery industry and contributes new concepts for the further development of urban mining.

EFFICIENT COOLING FOR HIGH-SPEED DRIVES | Fuel cell systems place high demands on air path components, as a reliable supply of oxygen to the stack is critical to performance. Electric air compressors, in particular, must reach high speeds, which leads to significant heat generation and can affect the system’s efficiency and service life. At Fraunhofer IFAM, an electric air compressor with integrated internal liquid cooling was therefore developed. Thanks to a specifically designed cooling system, the heat generated can be dissipated directly in the rotor via the shaft, thereby avoiding critical temperature ranges. The goal is to significantly increase the power density and reliability of fuel cell systems while ensuring safe operation at high speeds.

With the UAS L USSP HB project, a prototype system for a future U Space Service Provider (USSP) is being developed in Bremen. As a central entity, the USSP enables the safe and efficient integration of unmanned aircraft systems (UAS) into existing air traffic in accordance with EU Regulations 2019/945, 2019/947, and 2021/664. The goal of the project is to prepare the UAS Control Center Bremen for certification readiness.

Fraunhofer IFAM is pursuing two focal points in the field of electric drives: Firstly, the transformation of development processes and secondly, manufacturing innovations for electric drives.

PROJECT »TRANSPORTATION IN CHARGE« | In the project "Transportation in Charge", experts from Fraunhofer IFAM are developing concepts for the future planning of charging infrastructure in commercial areas and freight villages. The project aims to gain a better understanding of the demands for public and private charging infrastructure and to identify possible synergy effects through its shared use, thus ensuring the efficient utilization of this cost-intensive infrastructure.

QUALITY ASSURANCE AND GALVANIC CUSTOMER SOLUTIONS FOR IMPLANT MATERIALS | Many properties of implant materials, e.g. biocompatibility, cell adhesion, wetting behavior and corrosion, depend to a large extent on the chemical and morphological structure of the surface. With the aid of quality assurance concepts for the evaluation of surface properties, it is possible to gain detailed knowledge of these; thus, possible damage to health can be avoided. Fraunhofer IFAM provides support in this area and, with its extensive knowledge of surface technology (e.g. also in wet chemistry), can, among other things, create innovative process-oriented development concepts to improve the properties of implant materials.

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.

The transformation of natural gas supply is a key component of the heating transition. In the "Quarter by Quarter" project, Fraunhofer IFAM is investigating how existing energy infrastructures can be systematically decarbonized and made fit for the future, as natural gas supply must be transformed in line with the goal of climate neutrality by 2045.

A broad spectrum of additive manufacturing processes is being researched at the Bremen and Dresden sites. All of them are characterized by enormous geometric freedom, a high degree of individualization and excellent raw material efficiency. Occuring along the entire value chain: from the generation of 3D data models and manufacturing to the final machining and inspection of the components.

The joint project HERA, funded by the German Federal Ministry for Economic Affairs and Energy within the framework of the Aviation Research Program LuFo VII-1, aims at the development and validation of CFRP technologies for innovative, high-rate capable and sustainable fuselage backstructure parts (frames, door surround structures, small components) for future aircraft generations. The industrial research focuses on the specialist discipline of manufacturing processes for CFRP structures as well as the development of optimized architectural concepts in fiber composite construction in order to achieve maximum weight savings for the entire fuselage. By the end of the project period, the technological feasibility is to be demonstrated through the production of validators and the process chains are to be evaluated with regard to high-rate capability, cost efficiency and sustainability.

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.

SAFE AND POWERFUL SOLID-STATE BATTERIES BASED ON POLYMERS AND SULFIDES FOR ELECTRIC CARS, AIR TAXIS, MOBILE ROBOTS AND CO. | Solid-state batteries are an important building block for the electrification of mobility: They are safer and enable higher range and shorter charging times than conventional Li-Ion batteries. New cell concepts allow even higher energy densities. Fraunhofer IFAM is developing polymer and sulfide-based solid-state batteries for various electric mobility application areas. The research is oriented towards industrial battery production and ranges from development of new materials for solid electrolytes and battery components (electrodes and separators) to manufacturing process steps and cell assembly.

SUSTAINABLE AND EFFICIENT ROTOR BLADE MANUFACTURING WITH EMISSION-REDUCED SURFACE FORMATION PROCESSES | The manufacturing of large fiber-reinforced plastic (FRP) structures for wind turbine rotor blades is a complex process. Until now, release agents have been used that not only require labor-intensive reworking, but also have critical health and environmental impacts. Residues of these release agents on the surfaces prevent direct paintability of the components, making a time-consuming post-orocessing e.g. a sanding process necessary. This process generates considerable amounts of critical grinding dust. In addition, accessibility is limited due to the dimensions of modern rotor blades, both onshore and offshore. Fraunhofer IFAM has developed an alternative solution: a transfer-free release film that does not require any release agents and thus enables clean surfaces that can be painted directly. Building on this, the research project NEOFOIL has been launched.

Fraunhofer IFAM has tested optical components in collaboration with the Japanese company Asahi Kasei. The Japanese company Asahi Kasei manufactures the specially developed WGFTM polarizing film, which withstands strong mechanical and thermal stresses. Additionally, this film has good and uniform transmission and reflection properties across the entire visible and infrared spectral range. In the latest development, this film has been incorporated into finished optical components such as camera filters and polarizing beam splitters.

COUNTERING DIFFUSION AND EMBRITTLEMENT IN THE STORAGE AND TRANSPORT OF HYDROGEN | Green hydrogen will play a decisive role in a successful energy transition. The development of new hydrogen technologies requires techniques and processes that enable the safe production, storage, distribution and use of hydrogen. Central material science challenges are the diffusion of hydrogen and the associated embrittlement of used material. The "Plasma Technology and Surfaces" department at Fraunhofer IFAM is researching how surfaces can be protected against this diffusion and embrittlement by treatment with plasmas or lasers. The focus is on internal coatings for tanks and pipes, but possible applications for electrolysers, bipolar plates, and fuel cells are also being investigated.

The aviation industry is undergoing change: Innovation cycles are becoming shorter, and production and manufacturing requirements regarding cost-effectiveness, emissions, and environmental sustainability are increasing. To meet these challenges, the aircraft components of the future must be more cost-effective, flexible, and environmentally friendly. The Fraunhofer IFAM supports this transformation in the "MORPHO" project. The goal: a quieter, more efficient, sustainable, and economically viable aviation industry of tomorrow. Using an aircraft turbine blade as an example, our researchers have demonstrated the potential of integrated sensors.

We strengthen your team’s technical understanding and build a solid foundation for reliable, low-defect casting processes.

A NEW GENERATION OF GAP FILLERS FOR HEAT DISSIPATION FROM BATTERIES IN E-CARS | Heat dissipation from batteries is essential to protect them from overheating. This increasingly affects the batteries used in e-cars and other electric vehicles. Only if the batteries are protected from overheating, strong drive performance and long vehicle life can be ensured. This is enabled with gap fillers.

PRINTED CONDUCTIVE STRUCTURES MADE OF SPECIAL ALLOY | Fraunhofer IFAM has the expertise and equipment to produce printable metal and alloy inks for special applications. These inks made from special alloys for digital printing techniques offer opportunities for cost-efficient new products in the field of printed electronics and sensor technology in a wide range of industries.

STRESSES IN THE BOND LINE AFTER ADHESIVE CURING - CAUSE AND EFFECT | The most common causes of stresses in bond lines during adhesive curing are the volume reduction of the adhesive due to curing and different thermal expansions of the adhesive and the joined parts or of two different joined parts. When designing adhesive bonds, the question of volume reduction, also known as curing shrinkage, is crucial. It is important to determine the material value and understand how much volume reduction actually causes stress.

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.

METHODS FOR APPLYING SEALANT TO BIPOLAR PLATES USING SCREEN PRINTING | Fraunhofer IFAM is your competent partner for innovative research services in the field of fuel cell production. In addition to industrial projects in this context, we are active in public research projects - including the National Action Plan for Fuel Cell Production (H2GO). The National Action Plan maps the key sensitivities of the value chain in the production, stacking and recycling of substantial fuel cell components. Fraunhofer IFAM is, among other things, researching the use of the screen printing process for applying sealants to bipolar plates, which has several other advantages in addition to reducing production costs.

RECYCLING OF FUEL CELLS: ADHESIVE STRATEGIES FOR ASSEMBLY AND DISASSEMBLY | Fuel cells are an elementary component for the use of climate-friendly hydrogen in the transport sector. Fraunhofer IFAM is part of the technology alliance Stack2P in the national project H2Go in the national action plan for fuel cell production funded by the ministry of transport. A central goal is the development of recycling-friendly manufacturing technologies for fuel cells based on the principle of “Design for Recycling” and the implementation in an assembly and disassembly platform for the subsequent transfer of the components into scalable reuse, repair and recycling concepts. The goals are to increase product quality and reduce the product development cycle and development costs as well as reduce production errors.

MECHANICAL JOINING TECHNOLOGIES AND ADHESIVE BONDING: THE BEST OF BOTH WORLDS IN HYBRID JOINTS | Hybrid joints combine different joining technologies and are increasingly used in various industries. The decisive strength of a hybrid joint is that advantages of the elementary joining technologies are used and disadvantages are compensated. Adhesive bonding can be advantageously combined with various mechanical joining processes, depending on the application and industry. Fraunhofer IFAM develops solutions for various industries, for example for transportation, white goods, or construction.

PROJECT “BioRUHM”: REACTIVE URETHANE-FREE HOTMELT ADHESIVE | Reactive hot-melt adhesives (RHM) based on isocyanate are increasingly being used due to their exceptional properties, from packaging to automotive construction and technical textiles. However, the composition of these urethane-based adhesives also involves risks, e.g. the release of hazardous isocyanate. In the “BioRUHM” project, Fraunhofer IFAM is working with project partners to develop a urethane-free concept.