Technologies

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

With its expertise in the field of casting technology, Fraunhofer IFAM supports industrial customers in the casting technology implementation of an idea from the concept to the first prototype to the applicable product. Different casting processes and materials are available suitable for the respective problem.

TARGETED PRODUCT IMPROVEMENTS BASED ON IN-DEPTH KNOWLEDGE OF FRICTION AND WEAR | Whether motors and pumps as a whole or their seals - almost every application product is affected by friction and wear. The consequences are high energy losses and a shortened service life of the products. To counteract this, Fraunhofer IFAM is working intensively on tribology, i.e. the question of how friction and wear can be reduced or how lubrication between components can be improved. This is because these factors are directly influenced by various things such as material selection, surface coating, or contact geometry. With its broad spectrum of competencies in the fields of materials research, coating technology and analytics, the institute offers ideal conditions for developing holistic tribological solutions.

DETERMINATION OF MATERIAL AND SMALL COMPONENT PROPERTIES OF POLYMERS, COMPOSITES, AND ADHESIVE JOINTS AT CRYOGENIC TEMPERATURES | Fraunhofer IFAM offers outstanding possibilities for material testing at extremely low temperatures. In addition to tests in liquid nitrogen at -196°C, we can also carry out tests in gaseous nitrogen at temperatures down to -180°C.

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.

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.

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.

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.

INTEGRATION OF HIGHLY ELECTRICALLY AND THERMALLY CONDUCTIVE FILLERS IN A PLASTIC MATERIAL | Fraunhofer IFAM is specialized in the compounding of highly filled special polymer composites and the further processing into printable composite filaments. For the processing or production of filaments from polymer composites, the institute has comprehensive know-how and the latest technologies and process techniques. The composition of the material (fillers, filler content) and the selection of the base polymer are customized according to the customer's specific requirements.

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.

KEY TECHNOLOGY FOR EMC PROTECTION AND CAMOUFLAGE TECHNOLOGY | Radiation-absorbing materials (RAM) are becoming increasingly important in numerous industries. Whether in military technology, measurement technology, or automotive engineering - wherever sensitive electronics and high-precision sensors are used, effective protection against electromagnetic interference (EMI) is essential. Modern composite materials offer tailor-made solutions that can both shield electromagnetic waves and minimize radar and sensor signatures.

THIN SEPARATORS MADE OF SULFIDE OR POLYMER USING A SLOT DIE | Solid-state batteries with high energy density require thin separators made of sulfides or polymer electrolytes with layer thicknesses of less than 30 micrometers. With slot die coating, we can apply slurry tailored precisely to requirements and produce separator layers. The production and characterization of these layers requires expertise in materials, processes, and analytical methods, which are bundled at Fraunhofer IFAM.

With the steady increase in electronic assemblies and their use, for example in motor vehicles and sensors, the demands on their long-term stability and functional reliability are also rising. Polymer potting is an ideal way to protect these components.

Metal injection molding (MIM) is the key process when it comes to the economical series production of high-precision, complex metal components. MIM combines the design freedom of plastic injection molding with the mechanical properties of metallic materials. Fraunhofer IFAM has been one of the leading research institutions in this field for over 30 years and supports industry partners in implementing innovative material and component solutions in new products.

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.

VUV RADIATION OPTIMIZES SILICONE PROPERTIES AT THE SURFACE | We encounter silicone elastomers in many different areas. Due to their high elasticity, very good temperature resistance and biocompatibility, they are suitable for a wide variety of applications, for example in medical or food technology. The surface properties of the material, on the other hand, are not ideal and make it difficult to use in certain applications. For example, silicones are susceptible to wear, attract dirt, and can only be bonded to a limited extent. At Fraunhofer IFAM, a process has been developed which allows the surfaces to be modified quickly and flexibly without impairing the excellent mechanical properties of the silicones.

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.

Building blocks from nature that have already been perfected through evolution are ideally suited for developing new materials and surfaces with different functionalities. These can be antimicrobial, biocompatible or biodegradable, for example, depending on the requirements. As an institute focusing on adhesion and surface technology, our goal is to generate properties that are required for specific applications with respect to adhesion. In doing so, we work primarily with classical building blocks from nature such as sugars, fats and proteins and biobased polymers derived from them.

The development and evaluation of customized materials and adhesives is a central focus of our institute's work. Adhesives as composite materials play a major role in this. The outstanding properties of these adhesives are due to the fact that the composite has different properties than the individual components. This is also where the great potential lies, because there is a wide range of raw materials that - cleverly formulated - can optimize the final properties of an adhesive. This gives the adhesive certain properties, such as electrical or thermal conductivity, toughness, flame retardancy and also recyclability, which is increasingly in focus.

Increasing demands on productivity, resource efficiency and health protection require very special adhesives for many applications. This requires special formulations that are often not yet available on the market. This is where we are the right development partner. The focus of our R&D work is on harnessing novel raw materials for adhesives with previously unattainable properties, such as debonding on demand or extreme fast curing. The issue of sustainability is also becoming increasingly important for companies. Here we focus on the use of renewable and toxicologically safe raw materials in reactive polymer systems.