Projects completed 2025

The Bio-CO₂ Polymers project investigated how carbon dioxide (CO₂) can be used as a sustainable raw material for plastics. The goal was to convert CO₂ into dihydroxyacetone (DHA) using an enzyme cascade. At Fraunhofer IAP, the focus was on converting this intermediate product into polymerizable building blocks. These were used to produce aliphatic polycarbonates as new bio-based plastics. RWTH Aachen University developed the biocatalytic conversion process, while other partners supported the project with analyses and evaluations. The goal was to demonstrate how fossil raw materials can be replaced and emissions reduced.

The goal of the Bio-Resins project was to further develop bio-based polyester resins for industrial applications. The project was based on resins derived from 2,5-furandicarboxylic acid, which serve as a sustainable alternative to petroleum-based raw materials. The aim was to adapt these materials for use in semi-automated processes such as vacuum infusion, SMC, and relining. This specifically addresses applications in composite manufacturing. The project contributed to replacing fossil-based raw materials and enabling more sustainable production processes. It is part of the Joint Industrial Research program and is funded by the government.

To date, there have been few solutions for the efficient recycling of bio-based textiles. The BioTexCirc project therefore investigated whether such materials can be chemically recycled. The focus was on polyamides 6.9, 4.10, and 11, which are particularly relevant to the textile industry. In addition to technical feasibility, economic and societal impacts were also considered. The goal was to develop practical approaches for a sustainable circular economy.

The HarzForFree project developed an electroenzymatic process to produce glycolaldehyde from bio-based ethylene glycol, thereby replacing the harmful formaldehyde in amino resins. To achieve this, enzymes were combined with electrochemical processes to increase yield and create stable reaction conditions. The feasibility of the process was demonstrated: An enzyme system was successfully produced and coupled with electrochemical regeneration, resulting in higher product yields. For a second enzyme, suitable operating conditions with stable electrodes were developed. Both approaches were successfully integrated into an electrochemical cell. However, the yields achieved so far are still low, so further optimization is necessary.

Maintaining soil health is of central importance for the sustainability of agriculture and a key factor in productivity. As a result of various anthropogenic influences, including climate change, soil resources and their sustainability are under serious threat. The soil microbiome is highly complex and influences the production of bioactive metabolites, the regulation of plant health, and protection against pathogens. To enable optimal colonization by microorganisms and thus benefit the plants, live bacteria (probiotics) are necessary. So-called prebiotics serve as a food source for these bacteria but can also act as selection agents. In this project, probiotic bacteria were combined with substances having a prebiotic effect and designated as synbiotics to increase the survival probability of microorganisms living in the soil.

This project developed eco-friendly UV-protective active ingredients derived from renewable raw materials for use in cosmetics, particularly sun care products. The goal was to achieve a balanced triad of safety, efficacy, and sustainability. Initial prototypes were created in the laboratory, collaborations with industry and research partners were established, and the current state of knowledge was systematically evaluated. The results provide practical samples and a solid foundation for further product development. The active ingredients offer reliable UV protection and enhance formulations by providing a pleasant feel on the skin and a stable texture. In this way, the project paves the way for modern, sustainable sun protection products in the consumer care sector.

The goal of the project was to develop starch-based adhesives for folding carton production. These adhesives were intended to offer a sustainable alternative to conventional synthetic emulsion adhesives and to be tailored for modern high-speed machines. The focus was on reliable processing via industrial nozzle application, very short setting times with high adhesive strength, and a selection of raw materials designed to ensure high food safety and improve the recyclability of the packaging.

Press release

The goal of the EU project VITAL was to develop and validate innovative processing technologies for bio-based thermoplastic foams. The project addressed the need to replace petroleum-based plastics with sustainable, high-performance, and cost-effective alternatives in order to reduce the plastic industry’s environmental footprint. The applicability of these new materials was demonstrated by developing prototypes for the automotive industry, household appliances, and shipbuilding. The Fraunhofer IAP’s core task was to develop new foamable polyamide materials based on a bio-based building block.

In the Bio4Value project, Fraunhofer IAP worked with partners to develop an innovative membrane technology for the efficient processing of biogas. At the heart of the development were novel flat membranes that separate methane and CO₂ directly from wet raw biogas without the need for energy-intensive pre-drying. This significantly simplified the process and made it more economically attractive, particularly for smaller, decentralized biogas plants. The separated gases can be used in a variety of ways: methane as a bio-based energy carrier or chemical feedstock, and CO₂ as a starting material for industrial processes. The membranes developed at Fraunhofer IAP are characterized by high selectivity, mechanical stability, and resistance to hydrogen sulfide. The goal of the project was to further scale up the technology and translate it into marketable, modular systems for practical application.

The Power-to-MEDME R&D project supported the large-scale ramp-up of green methanol and dimethyl ether (DME) production in Chile. It examined the entire process chain—from green hydrogen production and CO₂ capture to the final product. The goal was to increase efficiency and reduce costs. Fraunhofer IAP focused on developing catalysts with reduced precious metal content for water electrolysis. In the process, a novel catalyst was successfully tested that exhibits high activity while requiring only a small amount of iridium. This helps conserve scarce resources and improve the technology’s cost-effectiveness.

Foot deformities primarily affect children and are often treated with custom-made orthoses. Until now, measurements have typically been taken using a plaster cast, which requires the child to remain immobilized throughout the entire curing process and is often associated with measurement errors. Current scanning systems capture only the static current state, but not the necessary dynamic corrective position. This must be done manually by the orthotist, which leads to a significant amount of rework. The R&D project aims to make the measurement process comfortable, reproducible, and performed directly in the required corrective position. To achieve this, a custom-fit sock made of shape-memory polymer is used, which holds the corrected position in place during the scan. The scanning device attached to the lower leg allows for measurement under real-world loading conditions and free movement.

The goal of the research project was to develop innovative connection and interconnection concepts for printed electronics in the aviation industry. To this end, requirements for the connections were defined in collaboration with experts from the aviation industry, and suitable concepts were developed. Prototypes were then manufactured and characterized, and were subjected in particular to environmental testing and long-term reliability assessments.

The Hydrogen Technology Initiative is part of the German federal government’s 7th Energy Research Program and supports the development and scaling of hydrogen technologies across the entire value chain. The initiative focuses on green hydrogen technologies for decarbonizing energy-intensive sectors, as well as on enhancing efficiency, cost-effectiveness, and industrial implementation. At Fraunhofer IAP, the focus was on the development of continuous-fiber-reinforced lightweight pressure vessels with integrated sensors for condition monitoring (SHM).

The MISEL project is developing an intelligent, energy-efficient vision system for use directly at the point of data collection (edge computing). Inspired by the perception of biological systems, it processes visual information in a manner similar to the human brain. At its core is a compact vision chip featuring multispectral sensors and neuromorphic data processing directly within the sensor. This allows data to be processed faster and with significantly lower energy consumption than with conventional solutions. The combination of neuromorphic processors, adaptive photodetectors, and integrated memory enables an autonomous, context-aware system. The goal is to provide powerful yet resource-efficient image processing for future applications.

The SIMPLE project prepared a proposal for an EU call for proposals under the Horizon Europe program, Cluster 3: Civil Security Research. The goal was to develop new approaches to reducing counterfeit goods, which represent a major source of revenue for organized crime. The focus was on establishing a suitable international consortium and drafting the content of the project proposal. To this end, partners from the research, business, and security sectors were involved.