Technologies

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.

MANUFACTURING OF FRP COMPONENTS USING A FUNCTIONALIZED RELEASE FILM | Due to their low weight and strength, components made of fiber-reinforced plastics (FRP) are in particularly high demand in a wide range of industries, such as the aerospace or automotive industries. However, conventional demolding of FRP components by using release agents is very cost and labor intensive. In addition, the release agents can have harmful effects on the environment. At Fraunhofer IFAM, a plasma-coated release film has been developed which allows thermoset plastic components to be manufactured and safely demolded without the use of release agents. The component surface is free of contamination and can be painted or bonded directly.

PRECISION LASER CUTTING AND LAMINATION STACK PRODUCTION FOR ELECTRIC DRIVES | The core of an electric drive plays a decisive role in determining efficiency, power density, and overall performance. Precisely cut stator and rotor sheets reduce eddy current losses, enhance magnetic properties, and allow higher rotational speeds. Through high‑precision laser cutting of electrical steel and production‑oriented lamination stack design, we support both research and development projects as well as industrial applications.

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.

The combination of serial kinematics with external linear axes results in versatile and adaptable machine concepts for manufacturing, even for the production of large components.