Construction and manufacturing technologies

The department deals with the holistic design of fiber composite and plastic-based lightweight solutions, starting with material selection and development, through design to construction of the lightweight structures with associated tools, to manufacturing and recycling after the service life. Commercial software and calculation tools as well as in-house developed program systems are used. In addition, a wide range of testing technology can be used for comprehensive analysis and structural tests.

Services

Design and simulation

• design and simulation of structural components
• static, dynamic and NVH analyses, Operational strength   
• load introduction elements and joining technologies suitable for materials and load paths
• description of complex interactions between material, process and component
• data-based modeling using stochastic algorithms and machine learning
• holistic design of manufacturing processes: Resin infusion and injection processes (SCRIMP, RTM, VA-RTM, RIM),
  Thermoforming, Filament Winding, Automated Fiber Placement (AFP), Fused Deposition Modeling (FDM)
• multicriteria optimization

Structure test and analytics

• chemical analysis (spectroscopy and chromatography)
• analysis of thin films e. g. m-line spectroscopy
• thermomechanical characterization methods for polymers and composites
• mechanical testing of materials and components
• optical characterization methods e. g. optical crack detection
• operational stability and environmental simulation, e. g. VDA-test
• crash and impact
• non-destructive testing methods (µ-CT, US)
• fire test e. g. Cone Calorimeter

Equipment

Design and manufacturing technologies

Simulation and design

Along the product-oriented value chain, the Simulation and Design working group deals with the cross-industry development of energy-efficient lightweight solutions and associated manufacturing technologies.

From the initial idea, through prototype design, to manufacturing implementation of complex technology demonstrators, the focus is primarily on design, coupled structural and process engineering.

From the initial idea, through the design of prototypes, to the manufacturing implementation of complex technology demonstrators, the focus is primarily on the design, coupled structural and process simulation, as well as on the manufacture and testing of functionally integrative FRP designs.

Contact: Marcello Ambrosio, M. Sc.

Structural testing and analytics  

The analyses of thermal and mechanical properties of polymer materials, semi-finished products and components represent the core competence of the working group. In addition, investigations of fatigue strength are carried out with superimposed environmental simulations. The working group also has its own fire laboratory for determining fire resistance and classification according to building material classes.

Contact: Dr.-Ing. Dustin Nielow

Center for Sustainable Lightweight Technologies

The Center for Sustainable Lightweight Technologies focuses on materials development for efficient manufacturing technologies, design and simulation with stochastic optimization algorithms, and manufacturing with novel monitoring methods and testing of efficient and highly resilient lightweight structures with a special focus on hydrogen storage technologies.

Hybrid compounds and UV-curable reactive resins for novel manufacturing technologies, process simulation and the production of highly integrated lightweight structures, structural health monitoring systems for process and condition monitoring, new optimization algorithms and approximation strategies for manufacturing processes and complex lightweight systems, as well as mechanical, chemical, thermal container and material testing are the main focus areas within the project group's five fields of action.

Contact: Dipl.-Ing. Felix Kuke