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.

SMART WALLPAPER FOR EASY BATTERY AND RADIO-FREE INTEGRATION OF IoT DEVICES | Smart homes aim to install technical systems wherever they are needed in the house. However, the necessary power and communication connections are not always available. In the "ConText" project, Fraunhofer IFAM is developing a smart wallpaper that can be easily installed in living areas without great effort.

DIGITAL FINGERPRINT: FORGERY-PROOF IDENTIFICATION OF COMPONENTS | Digital production requires individual component identification, as this is the only way to digitally link production data with the physical components. Optically readable codes such as barcodes or matrix codes are established methods for recording and tracking components in production and logistics. However, these methods are subject to fundamental limitations in terms of the space required, the surface geometry and structure of the component, as well as the robustness of the marking against damage and manipulation. They are also easy to counterfeit and are therefore only suitable as a security feature to a very limited extent. Last but not least, in some cases modifications to the surface are undesirable, whether for functional, hygienic or aesthetic reasons. This is where Fraunhofer IFAM's fingerprinting process comes in.

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

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.

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.

Thermally conductive adhesives, potting compounds and gap fillers, also commonly referred to as TIM, are used wherever components are to be thermally contacted. Until a few years ago, the main area of application for these materials was in microelectronics, e.g. to reliably dissipate the heat loss from highly integrated circuits or power semiconductors into cooling systems. With the progress of electric vehicles, the market for such products has grown considerably. They have become an indispensable key component that ensures the performance and longevity of the vehicle battery. Future applications include electrical energy storage for wind turbines and in the field of electrolysis for the production of hydrogen.

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.

TESTING LABORATORY FOR PAINTS, COATINGS AND CORROSION | In the development of paints and coatings as well as the accompanying quality management, standardized suitability tests of the paint are necessary in order to obtain the most accurate characterization of the coating system. Fraunhofer IFAM offers a wide range of test methods to determine and verify adhesion, elasticity, hardness, chemical resistance, and weather resistance. Paint testing is carried out both on liquid paints and on cured coatings. Depending on the application, these are subjected to varying loads – under laboratory conditions or in outdoor weathering. For this purpose, the researchers use standardized test procedures, but also develop customized test and testing methods if required.

Corrosion poses a serious threat to the longevity and functionality of metallic components. It is caused by environmental influences and contact with corrosive media, leading to enormous economic damage worldwide. In an industrialized nation, the direct costs of corrosion are estimated to be around three to four percent of the gross domestic product (GDP) annually. Early prevention is therefore crucial to preserving assets and minimizing costs.

ADHESIVE FILMS AND COATINGS BASED ON BENZOXAZINE - STORAGE-STABLE AND NON-MELTABLE | Repairing fiber composite components is often time-consuming and requires multiple processing steps and curing cycles of the resin. Typical restoration of the function or appearance of a damaged area is carried out using a wet lamination process or application of reinforcing structures on the surface. Therefore, if an adhesive film or coating based on benzoxazines is used instead this enables comparatively simpler repair and adhesive bonding, with final strength being achieved within 30 minutes.

Reliable demolding, optimized efficiency and quality: release agent-free FRP large component production

DEVELOPMENT TEST BENCH FOR ENERGY- AND RESOURCE-EFFICIENT E-MACHINES | Fraunhofer IFAM has been engaged in research within in the field of electric drive technology for many years. To identify optimization potential at an early stage during the development of electric machines, the institute has electric motor test benches in the power range <3kW and in the range from 20kW to 100kW. The performance of new technologies, developments or concepts in electric drives can be assessed here – this includes, in particular, the characterization of the operating behavior of electric machines (prototypes) beyond merely gathering of simulation data, throughpractical experiments.

Thermodynamic calculations allow predictions about phase formation in materials during thermal processes, both during their manufacturing and under application conditions.

PROTECTIVE COATINGS FOR ELECTRONIC ASSEMBLIES - FOR ABSOLUTE OPERATIONAL RELIABILITY | An ever-increasing number of electronic assemblies must function with long-term stability, even under extreme operating conditions. Fraunhofer IFAM has a wide range of experience in the field of corrosion protection of electronic assemblies and is therefore the ideal contact for questions concerning the pretreatment and protective coating of these components.

PROTECTIVE COATINGS FOR ELECTRONIC ASSEMBLIES - FOR ABSOLUTE OPERATIONAL RELIABILITY | An ever-increasing number of electronic assemblies must function with long-term stability, even under extreme operating conditions. Fraunhofer IFAM has a wide range of experience in the field of corrosion protection of electronic assemblies and is therefore the ideal contact for questions concerning the pretreatment and protective coating of these components.

Nowadays, products such as adhesives, potting resins and matrix resins for fiber composites or coatings not only have to meet high technical and ecological standards, but also be economical and sustainable. The basis for meeting these requirements is already laid in the raw materials. At Fraunhofer IFAM, the development of novel raw materials, such as reactive polymers or additives, is therefore a focus of research and development work. The raw materials developed are tested in application-oriented formulations and specific applications. In addition, sample formulations based on new raw materials are developed at the institute, often also on direct order from raw material manufacturers.

PLAQUE AND PROLIFERATION ASSAYS FOR EFFICACY TESTING OF ANTIBACTERIAL AND ANTIVIRAL SURFACES AND COATINGS | Multi-resistant germs have been a serious problem in healthcare for years. Covid-19, an infectious disease caused by SARS-CoV2, made the concepts of hygiene and disinfection an everyday topic around the world. Consequently, the need for antimicrobial technologies (antimicrobial coatings, UV disinfection) increased in many entrepreneurial sectors, including healthcare, automotive, construction, and public transportation. This wide range of applications presents different technological challenges. Fraunhofer IFAM therefore tests antimicrobial efficacy against model viruses, bacteria, and fungi according to customer-specific requirements.

OPTIMIZING ICE PROTECTION ON AIRCRAFT, SHIPS AND WIND TURBINES BY MEANS OF ANTI-ICING COATINGS | Ice formation on surfaces causes high costs due to increased energy consumption, and lower energy yield. At the same time, it impairs function and safety. Affected are not only aircraft, ships, rail vehicles, and automobiles, but also cooling units and wind turbines. Fraunhofer IFAM is therefore developing and testing application-specific anti-icing technologies to prevent as well as remove icing on surfaces.

ENVIRONMENTAL SIMULATION FOR TESTING AND INSPECTION OF ANTI-ICE COATINGS | For the characterization of surfaces, laboratory tests under reproducible icing conditions are necessary to investigate ice formation and ice adhesion strength. This provides material developers with initial information on the performance of the surfaces. Fraunhofer IFAM determines the potential of newly developed icephobic coatings in application-specific laboratory tests.