Technologies

On the way to optimize robot systems, an extraordinarily powerful software application for model-based calibration of industrial robots has been developed by Fraunhofer IFAM in Stade which enables high-precision robot use.

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.

Fraunhofer IFAM has now developed a novel solution for the dynamic improvement of the kinematics: the hybrid drive for industrial robots.

HIGH-PERFORMANCE COMPOSITES FOR RELIABLE ELECTROMAGNETIC COMPATIBILITY | Electronic systems are everywhere – from complex machine controls and sensor technology in Industry 4.0 to electric drives in vehicle construction. This also increases the risk of electromagnetic interference that can affect other devices or cause sensitive systems to malfunction. Compliance with electromagnetic compatibility (EMC) is therefore essential for the trouble-free functioning of devices and the reliability of sensitive electronic equipment. At Fraunhofer IFAM, we develop innovative functional composites for EMC protection.

HYDROGEN BARRIER COATINGS FOR TANKS, PIPELINES AND MORE | For hydrogen tanks and the like, metallic materials (e.g. steel or aluminum) are still predominantly used today, either as solid materials or as liners in polymeric materials, which constitute an enormous additional weight. In order that lightweight materials such as fiber reinforced polymers can also be used for fuel tanks etc., which do not provide a sufficient barrier to hydrogen permeation themselves, Fraunhofer IFAM is developing barrier coatings which strongly reduce the permeability of hydrogen and thus offer versatile possibilities for lightweight construction in the aerospace industry, but also in other areas.

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.

Atmospheric pressure (AP) plasma can be used to clean, activate and coat surfaces efficiently and in an environmentally friendly manner. In industry, the process has now become established for pretreating surfaces prior to bonding, printing and painting processes in order to reduce the use of solvents (VOCs). In addition, the plasma-polymer nanolayers are used in production as corrosion protection, for environmentally friendly adhesion, for electrical insulation, or as a permanent hydrophobic release layer. Fraunhofer IFAM develops customized solutions using adapted processes and coatings with AP plasma for a wide range of applications.

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.

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 Powder Bed Fusion is a powder bed based additive manufacturing process that is most widely used in the industry. The Fraunhofer IFAM deals with material and process development along the entire process chain of laser beam melting. Our powder analytics can be used to characterize the flow behavior and packing behavior of the raw material powder, which significantly influence the construction parameters. The complete parameter development for various materials (titanium, aluminum or steel alloys) is carried out at Fraunhofer IFAM.