Technologies

ENERGY-EFFICIENT AND COST-EFFECTIVE BATTERY ELECTRODES THROUGH SOLVENT-FREE PROCESSES | The industrial scaling of new production processes for battery components is crucial for bringing innovative battery technologies into use. However, high-performance materials alone are not enough: they must also be processed using scalable, efficient, and sustainable manufacturing routes. This is precisely where Fraunhofer IFAM’s research comes in: Using innovative powder technologies and solvent-free electrode processes, the institute is developing new approaches to battery cell manufacturing and examining their implementation all the way through to industrial production.

At the Fraunhofer IFAM training and competence center for humanoid robotics in horticulture located in Stade, Germany, researchers are investigating how humanoid robots can acquire this empirical knowledge, combine it with existing artificial intelligence (AI) models for object recognition and use it to derive appropriate actions for specific situations.

POWDER METALLURGICAL AND CASTING PRODUCTION OF POROUS METALS | Metal foams, porous metals and hybrid materials based on them have an attractive range of properties due to their specific structures. They are used in many areas such as automotive engineering or medical technology to improve technical systems. The Fraunhofer IFAM offers various powder metallurgical and casting processes for the production of open- and closed-cell metal foams.

The "Center for Surface and Coating Technology" at Fraunhofer IFAM demonstrates the future of surface treatment. The state-of-the-art technical center has digitally linked industrial robots – such as painting robots – for the automated cleaning, pre-treatment, and subsequent painting of component surfaces in small and large structures. The entire process chain is digitally mapped and supplemented by interaction options using virtual and augmented reality. R&D goals include the realization of digitally networked surface technology systems and processes as well as process and quality optimization through machine learning and the use of AR/VR methods.

Corrosion is one of the greatest challenges for industry, infrastructure, and the environment. According to DIN EN ISO 8044:2025, corrosion is defined as the “chemical or electrochemical interaction between a material, usually a metal, and its environment.” This interaction can lead to material damage, functional failure, and enormous economic costs. In industrialized nations, 3-4% of gross domestic product is lost annually due to corrosion damage. The fact is that most of this corrosion damage could be avoided if existing knowledge were applied properly. Fraunhofer IFAM offers comprehensive solutions for corrosion protection, testing methods, and damage analysis – scientifically sound and accredited.

In the group Soft Magnetic Materials, innovative powder technologies are used to manufacture soft magnetic components with reduced losses or special property profiles. Different concepts are pursued depending on the requirements especially the frequency range.

The aging of bonded joints begins immediately with their manufacture. External stresses are decisive for their speed and thus their significance for the bonded component. The visible or measurable manifestations of aging are very diverse. For example, the glass transition temperature can decrease due to the degradation of polymer structures or increase due to plasticizer diffusion as well as incorporation of stiff molecular structures into the polymer chains. Specific functions of the adhesive, e.g. conductivities or damping, may deteriorate and / or the bond strength may drop. At Fraunhofer IFAM, we are investigating the aging of adhesives in order to sustainably improve/ensure the longevity of bonded joints.

FUNCTIONALIZABLE METAL SURFACES THROUGH PLASMA ELECTROLYTIC OXIDATION (PEO) | Plasma electrolytic oxidation (PEO), also known as micro arc oxidation (MAO), is a wet chemical process that enables the production of highly functionalizable oxide layers on metals whose oxides do not have electrical conductivity, such as aluminum, magnesium, or titanium. These coatings are hard, wear-resistant, heat-resistant, and porous, making them ideal for use in aerospace, medical technology, and other high-performance industries.

Green hydrogen is considered a key building block of the energy transition. At the same time, existing electrolysis processes face major challenges: hydrogen production is still costly and energy-intensive and requires highly purified water. This is exactly where the SeaEly project came in. Together with partners from research and industry, the Fraunhofer IFAM developed new components and testing methods for direct seawater and brackish water electrolysis. The aim was to enable efficient hydrogen production even with challenging water qualities — without the need for complex desalination processes.

YOUR GRID CONNECTION DOES NOT ALLOW FAST CHARGING? | At Fraunhofer IFAM, simulation calculations can be used to consider and analyse the effects on the entire energy system associated with the installation of charging infrastructure.

REAL LABORATORY WITH CHARGING STATIONS, STORAGE SYSTEMS AND PHOTOVOLTAIC SYSTEMS | Charging electric vehicle fleets at companies or public institutions without smart charging management can result in enormous costs or even overload the grid connection. To avoid this, the industry is turning to “smart charging.” This allows charging processes to be controlled in a way that meets demand and optimizes costs. The real laboratory at Fraunhofer IFAM offers the opportunity to test, analyze, and specifically develop such solutions under real-world conditions.

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.

ENVIRONMENTAL SIMULATION FOR TESTING AND INSPECTION OF ANTI-ICE COATINGS | For the characterization of surfaces, laboratory tests under reproducible icing conditions are necessary to investigate ice formation and ice adhesion strength. This provides material developers with initial information on the performance of the surfaces. Fraunhofer IFAM determines the potential of newly developed icephobic coatings in application-specific laboratory tests.

HIGH-PERFORMANCE TEST ENVIRONMENT FOR ELECTRIC MOTORS AND ELECTRIC DRIVE SYSTEMS | The test bench for electric machines at Fraunhofer IFAM enables comprehensive testing and validation of electric motors and electric drive systems under realistic conditions (both in the power range <3 kW and in the range from 20 kW to 100 kW) . This allows the performance, efficiency, and operational behavior of electric motors to be reliably investigated and optimized - even during development.

HOW OUR NEW METHOD DETERMINES BATTERY CONDITION (SOH) DURING OPERATION | Until now, monitoring the condition of batteries has been limited: Many measurement methods provide inaccurate results or only work when the battery is at rest. This makes precise battery management difficult and can affect both battery life and safety. A new measurement method offers a solution. Researchers at Fraunhofer IFAM have developed a method that, for the first time, allows the condition of batteries to be analyzed in real time during operation.

PERMANENT RELEASE COATINGS ENABLE ENERGY-EFFICIENT AND MATERIAL-SAVING PRODUCTION IN LIGHTWEIGHT CONSTRUCTION | In the production of plastic parts from reactive resins such as epoxies or polyurethanes, conventional release agent systems are generally used for demolding, regardless of the manufacturing process. These contaminate both the component surfaces and the molds (mold buildup). In addition, they often contain environmentally harmful solvents and other auxiliaries. Employees and the operating environment are also contaminated by very fine, long-lived aerosols. The mold structure and, if necessary, the release agent-contaminated components have to be cleaned in subsequent steps - with negative consequences for productivity, energy consumption, and the environment. Fraunhofer IFAM has developed a ReleasePLAS® release coating for molds which completely avoids the use of these conventional release agent systems and the associated disadvantages.

MODIFYING AND COATING SURFACES COST-EFFECTIVELY WITH LOW-PRESSURE PLASMA | Low-pressure plasma offers a wide variety of surface modification options. They range from activation and fine cleaning to customized functional coatings. Low-pressure plasma processes are characterized by low costs, minimal material consumption and high process reliability. Another advantage of this process technology is its adaptability to product changes. For example, material or geometry changes can be implemented quickly and easily. The use of large-volume systems also makes it possible to treat a large number of components simultaneously, so that the total cost of ownership (TCO) is low.

Humanoid robots open up new possibilities for industry, crafts, horticulture and agriculture – especially in areas where traditional automation reaches its limits.

Reliable demolding, optimized efficiency and quality: release agent-free FRP large component production

INNOVATIVE SOLUTIONS FOR SUSTAINABLE COOLING TECHNOLOGIES | Magnetocaloric cooling systems offer industry a pioneering alternative to conventional compression refrigeration machines – technologically innovative, economically attractive, and ecologically sound. Instead of conventional refrigerants, these systems use the magnetocaloric effect: By making targeted changes to the magnetic field in specially developed materials, cold can be generated efficiently and in a controlled manner – without the use of fluorinated greenhouse gases.

PRODUCTION OF METAL AND CERAMIC COMPONENTS BY MEANS OF EXTRUSION AND SINTERING | Extrusion is one of the most common shaping processes for producing elongated structures with constant, often complex cross-sections. Products produced by extrusion include tubes, hoses, or even V-belts and toothed belts. In its research work, Fraunhofer IFAM focuses, among other things, on powder extrusion. This involves extruding thermoplastic molding compounds with high proportions of metal or ceramic powders and then debinding and sintering them. The focus is on material development and adaptation along the entire process chain in order to achieve optimum results for the individual needs of our customers.