Lightweight construction is a key technology that will ensure that Germany remains a viable industrial location in the future. The Polymer Materials and Composites PYCO Research Division at Fraunhofer IAP plays an important role in this. The team at the Wildau and Cottbus sites develops customized lightweight construction solutions – from monomers to energy-efficient high-performance composite components.
Lightweight construction encompasses innovative manufacturing technologies and products that reduce manufacturing and operating costs and enable a more efficient use of resources. Particularly in areas such as mobility, construction, mechanical engineering and energy technology, lightweight construction makes it possible to reduce the environmental impact of CO2 emissions. The integration of extended functions and the development of load-optimized designs continuously opens up new markets.
Scientists at Fraunhofer IAP are developing mobile spherical hydrogen storage units made of carbon fiber reinforced plastic (CFRP) as part of the TransHyDE project Mukran. The entire project is being funded by the Federal Ministry of Education and Research and will receive around 19 million euros. Six partner institutions are working together on the project. Unlike conventional cylindrical tanks, spherical tanks are a perfect compromise between load and functional geometry. The lightweight spherical storage tanks are characterized by their low weight and high storage capacities. The scientists are focusing on the design and development of the manufacturing process. The team is also integrating a structural health monitoring system which will monitor the tanks throughout their service life. Aging processes and potential leaks can thus be tracked at an early stage and on an ongoing basis. The development of these spherical storage tanks is an important step in decentralizing the supply of hydrogen and transporting it by truck, train or ship.
In February 2023, the joint lightweight construction initiative was launched by the economic ministries of Berlin and Brandenburg. The initiative aims to pool and strengthen expertise in lightweight construction. It initiates new research projects and collaborations to develop and implement innovative lightweight construction solutions. It also promotes dialog between science, business and politics and supports regional industry in the development and implementation of modern lightweight construction technologies. Professor Holger Seidlitz, head of the Polymer Materials and Composites PYCO Research Division at Fraunhofer IAP, presented the institute’s lightweight construction expertise at the launch event. This expertise ranges from the development of tailor-made high-performance polymers for fiber-plastic composites and complex fiber composite components, to the design and construction of plastic-based lightweight solutions. The researchers at Fraunhofer IAP focus on sustainable material cycles in order to create products that are both resource and energy efficient. For example, they are currently developing a very lightweight drive and side shaft system for cars and trucks whose matrix consists of thermoplastic materials. The components are recyclable. Digitalization and intelligent designs are also playing an increasingly important role.
Another event in February 2023, was the visit by Dr. Manja Schüle to Fraunhofer IAP in Wildau. The Minister of Science, Research and Culture of the State of Brandenburg learned about the latest developments in lightweight construction and the institute’s research projects. She particularly emphasized the importance of this area of research for the region. The cooperation between PYCO in Wildau, the Brandenburg University of Technology and the Fraunhofer facilities in Cottbus is providing important impetus in Lusatia which will successfully shape structural change and transfer technologies from research to application.
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