Technologies

RAY TRACING FOR OPTIMIZED SURFACE TREATMENT WITH LIGHT | The irradiation of surfaces with light is a common procedure in surface technology. It can be used, for example, to clean or activate surfaces before the adhesive bonding or coating process. Currently, there is also great interest in the disinfection of surfaces with UV light. In order to design and optimally configure irradiation systems, researchers at Fraunhofer IFAM simulate light distribution and intensity with an algorithm that has recently gained publicity for its application in 3D computer graphics: ray tracing.

INLINE-BLASTING PROCESSES FOR CLEANING, ACTIVATION AND REPAIR OF SURFACES | Classical compressed air blasting requires the use of blasting booths or complex temporary protective measures to clean surfaces or remove coatings. Much simpler is to use compact and mobile vacuum suction blasting prior to, for example, adhesive bonding, painting/lacquering, coating, or repair work. In this method an industrial vacuum system generates a reduced pressure in a closed head through which the abrasive is accelerated onto the surface and after the blasting process is immediately extracted again. This means that dust-free blasting processes can even be performed in-line under sensitive production conditions.

LASER TECHNOLOGY ENABLED STABLE INTERFACES FOR METAL HYBRID CASTING AND PLASTIC INJECTION MOLDING TO INCREASE COMPOSITE STRENGTH | Laser technology offers optimal possibilities for the pre-treatment of surfaces. Researchers at Fraunhofer IFAM have succeeded in achieving a significant increase in composite strength in metal-metal, metal-plastic or plastic composites by means of laser pre-treatment. The high interfacial strengths result from positive and non-positive micro-interlocking between the laser-treated component and the infiltrated metal or plastic. Innovative laser-induced channels on components, which enable complete infiltration with melts or plastics, are fundamental. In addition, production time and costs can be saved compared to conventional joining methods by integrating the joining process into the primary forming process.

SELF-HEALING COATINGS – FOR SUSTAINABLE PROTECTION AND EXTENDED DURABILITY | Self-healing coatings represent an innovative approach to protecting surfaces against wear and damage over the long term. These intelligent materials can repair minor damage in coating layers either autonomously or through external stimuli such as temperature changes, humidity, or UV light. The technology offers versatile applications, particularly for reducing maintenance costs and extending the lifespan of coated surfaces.

RESIDUE-FREE AND DRY CLEANING OF COMPONENTS | Contaminants and release agents can be removed from components using CO2 snow blasting processes. This in-line technique involves the sudden expansion of liquid CO2, whereby solid crystals of CO2 snow form in a nozzle on introducing compressed air. These are blasted at the surface to be cleaned. There is no damage due to the immediate sublimation, and even sensitive surfaces can be effectively cleaned. Compared to conventional blasting grit, the CO2 snow evaporates and can be extracted without leaving residues. The process is eco-friendly because CO2 can be recovered as a byproduct from many chemical processes.

BIOCIDE-FREE FOULING PROTECTION AND FLOW-OPTIMIZED SURFACES FOR THE MARITIME INDUSTRY | Functional coatings against biofouling and corrosion are an important part of the maritime industry. They protect ships and other maritime infrastructure in the harsh marine operational environment.. Innovative coating technologies and materials are being researched at Fraunhofer IFAM to achieve effective and durable resistance to biofouling, corrosion, and mechanical abrasion, for example by underwater cleaning processes. This can reduce operating costs, extend service life and improve environmental protection. The development of high-performance antifouling coatings is an important step towards a sustainable maritime industry, which in the future will focus, among other things, on the climate neutrality of ships and the expansion of renewable energies at sea.

EFFICIENT PLASMA COATING WITH CUSTOMIZED NOZZLES | Inline Coating with Atmospheric Pressure Plasmas has established itself as a sustainable solution in industrial manufacturing. This technology offers, for example, environmentally friendly corrosion protection and enables secure adhesion of adhesives and paints – all without the use of harmful primers. Each industrial application scenario presents individual challenges: from coating width and accessibility of complex, three-dimensional components to the treatment of temperature-sensitive materials. At Fraunhofer IFAM, customized nozzle heads are developed to flexibly address these varying requirements.

ENVIRONMENTALLY FRIENDLY PLASMA COATINGS OPTIMIZE THE ELECTRICAL INSULATION OF COMPONENTS | In modern electronics manufacturing, reliable and efficient insulation solutions are indispensable. They protect electronic components from unwanted electrical contact, harmful environmental influences, and premature aging. Plasma-polymer thin-film systems are PFAS- and halogene-free and offer optimized solutions in this context. These technological innovations combine advanced material properties with a sustainable manufacturing process, providing an attractive alternative to conventional insulation methods such as potting compounds and lacquer systems. At Fraunhofer IFAM, plasma technology is used to produce ultra-thin, partial-discharge-resistant layers in the micro- and sub-micrometer range, significantly enhancing the performance and longevity of electronic components.

ROBOT-ASSISTED SURFACE PRE-TREATMENT FOR SERIES PRODUCTION | In modern process chains, multi-axis gantry systems and industrial robots are indispensable. At Fraunhofer IFAM, this potential is utilized to develop tailored solutions for industrial surface pre-treatment. Thanks to the available robotic technology, we can optimally support our customers from laboratory trials and feasibility studies to the complete manufacturing process.

Non-stick coatings have been among the most popular coatings for cookware such as pans, casseroles or cutlery for decades due to their ease of use and cleaning. Common nonstick coatings are made with a PTFE or sol-gel base. However, PTFE-type coatings face a ban in the near future due to possible PFAS restrictions by the EU. In addition, these coatings have only limited durability and lose their non-stick effect over time. In addition, they are not very stable mechanically and have to be baked in an oven, which involves high energy consumption. New, sustainable solutions with good non-stick properties are therefore needed. Researchers at Fraunhofer IFAM have developed PLASLON® coating, a PFAS-free alternative, which is characterized by its excellent non-stick properties in combination with its high durability.