Research division Polymeric Materials and Composites PYCO

Polymer-based lightweight construction – energy efficient curing and functional imprinting

Alternative curing methods for composites is just one of the expertise of IAP’s PYCO research division. In addition to using UV LEDS to cure plastics and produce composites, microwaves are playing an ever-greater role in the curing process.

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Lightweight construction for aeronautics and transport: sustainably repairing and recycling CFRP components

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Polymeric Materials and Composites PYCO

Chemists, physicists, engineers and technicians of Fraunhofer sites in Teltow and Wildau are developing highly crosslinked polymers (thermosets) for all applications with particular reference to aviation, IT-technology and instrumentation.

Today, our work is particularly focused on lightweight composites and on micro as well as optoelectronics: new (nano-)materials, prepregs, core materials, laminates, all kinds of fiber reinforced materials, sandwich structures, bistable displays, integrated optical devices and barrier layers.

The application of our thermosets is in the field of adhesives, coatings, varnishes, binders, inmolds and gelcoats, castings, foams, prepregs, Resin Transfer Moulding (RTM) and pultrusion. The following properties can be designed into these resin systems: high flame retardancy, high fracture toughness, minimum volume shrinkage upon curing, fast and latent curing at a time, disbonding ability (e.g. with adhesives), barrier properties against water vapor and oxygen, adjusted thermal coefficient of expansion, adjusted refraction index, rework and recycling ability. As those properties are often in contrast to each other, we focus particularly on the combination and optimum balance of material properties like high Tg (glass transition temperature) along with high fracture toughness in a single system, just to mention an example.

We are developing polymer systems along the whole supply chain, beginning with the monomers up to the finished part. We synthesize monomers and prepolymers including or not one or more of the following: coreactants, flame retardants, tougheners, fillers or modifiers. Subsequently, we take efforts to ensure the processability of the systems and manufacture first prototype parts, mainly in close cooperation with our customers. We characterize the finished parts and work on quality assurance criteria. As a result, we are providing thermosetting polymer systems in any developmental stage as agreed between us and our clients. Those stages can be the reactive resin system itself, fiber reinforced materials, sandwich structures or any other demonstrator part that has been agreed upon.

Our services

  • synthesis and formulation of thermosetting resins
  • development and modification of polymers and composites for applications in lightweight design, as well as in the fields of micro- and optoelectronics, adhesives, underfillers, coatings, laminating and casting resins, foams, thin functional layers, prepregs, laminates, and sandwiches
  • characterization and testing of polymers and composites
  • processing of polymers (also as composites with other materials)
  • application-oriented analysis for product introduction
  • preparation of studies and expert reports
  • consulting

Material development

  • fiber-reinforced polymers, multilayer composites, core materials, sandwich structures (also in combination with other materials, e.g. metals)
  • prepregs, laminates
  • adhesives, fillers, coatings, laminating casting resins, foams, thin functional layers
  • integrated optical components, barrier layers
  • radiation-curable thermosets (UV, microwave, e-beam)

Our equipment

Pilot plants


  • horizontal and vertical pilot impregnation plants
  • microwave (8 m³ microwave oven and continuous microwave plant) equipped with dielectric spectroscopy
  • UV curing (UV LED systems and mercury-vapor lamps)
  • 190 keV electron-beam plant



Research division Polymeric
Materials and Composites PYCO   


Location Teltow


Kantstraße 55
14513 Teltow
Phone +49 3328 330-284
Fax +49 3328 330-282


Research division Polymeric
Materials and Composites PYCO   


Location Wildau


Technical Center 1 | Freiheitstraße 124-126
Technical Center 2 | Schmiedestraße 5

15745 Wildau
Phone +49 3375 528 823 00


Department of polymer-based lightweight construction


Location Cottbus


BTU Cottbus - Senftenberg | Panta Rhei Hall
Konrad-Wachsmann-Allee 17
03046 Cottbus

Phone +49 355 69 2059

Christian Dreyer

Contact Press / Media

Prof. Dr. Christian Dreyer

Head of department | Resin Formulation and Characterization | Head of department | Thermosets for Lightweight Applications

Kantstraße 55
14513 Teltow

Phone +49 3328 330-280

Fax +49 3328 330-282

Mathias Köhler

Contact Press / Media

Dr. Mathias Köhler

Head of division| Radiation and Rapid Curing Systems

Kantstraße 55
14513 Teltow

Phone +49 3328 330-278

Sebastian Steffen

Contact Press / Media

Dr. Sebastian Steffen

Head of department | Resin Synthesis and Semi-finished Components

Kantstraße 55
14513 Teltow

Phone +49 3328 330-246

Polymeric Materials and Composites PYCO