Technologies

We cover the complete value chain for the additive processes we have available at Fraunhofer IFAM – from the creation of 3D data models, through manufacturing, to final processing and inspection of the components.

PREVENTING FAILURE IN LOAD-BEARING STRUCTURES MADE OF FIBER COMPOSITE AND ALUMINUM | The use of composite materials in load-bearing applications is continuously increasing in various industries, especially in the railroad, automotive, aerospace and wind energy sectors. Even the smallest damage, such as cracks in load-bearing structures, requires repairs to prevent so-called fatigue crack growth, which in the worst case can lead to structural failure. Bonding solutions are promising in this respect. Patch adhesive repairs have also proven to be extremely effective for lightweight aluminum structures. Compared to conventional repair methods such as riveting or welding, bonded repairs offer several advantages.

MECHANICAL TESTING, COMPONENT SIMULATION AND TESTING OF BONDED JOINTS | Fraunhofer IFAM has a materials testing laboratory certified according to DIN EN ISO 9001:2015. This laboratory is accredited according to DIN EN ISO/IEC 17025:2018 for the procedures specified in the DAkkS certificate. Experiments are carried out to test materials, structures and, in particular, adhesively bonded joints according to standardized and self-developed procedures for example for the automotive industry or rail vehicle construction. The results of these tests form the basis for simulating component behavior. Many of the tests focus on the tensile behavior of fiber-reinforced plastics, but also on the impact strength and peel strength of adhesively bonded joints. Particularly in order to describe the complex behavior of adhesively bonded joints, the researchers also develop customized test methods as required.

DO YOU NEED CERTAIN PROPERTIES OF A METAL IN A PLASTIC? | Then Fraunhofer IFAM offers the solution with its developed polymer composites! The special compound technology of Fraunhofer IFAM makes it possible to produce special composites based on a wide range of thermoplastics and elastomers which are, for example, highly electrically and/or thermally conductive.

FUNCTIONAL INTEGRATION THROUGH PRINTING TECHNOLOGIES | The technology platform »Functional Printing« comprises digital and mask-based printing technologies, with which components can be functionalised specifically and precisely at the required component locations. Sensors or electronic components can thus be integrated into existing products and give the component additional or completely new properties and functions. Fraunhofer IFAM offers all important printing processes at its disposal and has in-depth material expertise. If printable inks or pastes are required for sensory applications, for example, which are not commercially available, these can be developed at Fraunhofer IFAM.

MORE FLEXIBILITY THROUGH MORE AXES | The use of industrial robots and 5-axis gantries systems makes it possible to print functions such as sensors or heaters on components with complex surfaces exactly where they are needed. Various printing technologies such as aerosol jet or dispensing can be used to print structure sizes ranging from a few micrometres to several metres. The systems at Fraunhofer IFAM can thus provide component sizes ranging from a few millimetres to 10 metres with a variety of different functions, such as conductor tracks, with pinpoint accuracy.

FUNCTIONALIZATION OF COMPONENTS USING PRINTING TECHNOLOGIES | For customized functionalization of components using printing technologies, suitable inks and pastes are required. Fraunhofer IFAM has extensive expertise and capabilities for the development of printable inks and pastes. These range from the selection of suitable functional and additive materials, to the production / homogenization of the pastes and inks, to the subsequent printing and curing process.

PRINTED ELECTRONICS AND SMD (SURFACE MOUNTED DEVICE) TECHNOLOGY - THE BEST OF BOTH WORLDS | The combination of printed electronics and SMD components opens up new design possibilities and integration options into products. Multilayer circuits can be printed layer by layer on a flexible film and then assembled. This technology not only offers great potential for lightweight construction, but is also an environmentally friendly alternative to the conventional multilayer PCB (printed circuit board) due to the absence of glass fibre composites.

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.

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.