Technologies

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.

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.

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.