Technologies

Fraunhofer IFAM develops cognitive, AI-based solutions that enable robots to perceive their environment and process state, assess changing situations and adapt their movements during task execution.

UNDERSTANDING AND OPTIMIZING INTERFACES | Surface and interface properties play a crucial role in the quality and performance of numerous products and industrial processes. Even the slightest contamination can affect coating and manufacturing processes, compromising their functionality. This applies to applications such as adhesive bonding, painting, printing, and metallization. Fraunhofer IFAM offers a wide range of analytical methods for comprehensive chemical and structural surface analysis at the nanoscale.

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.

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.

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.