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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Defekte Flugzeugbauteile aus carbonfaserverstärkten Kunststoffen könnten bald einfach und kostengünstig repariert oder recycled werden.

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 Wildau

 

Schmiedestraße 5

15745 Wildau

Phone +49 3375 2152-100

 

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 | Tailored Materials / Head of working group | Polymer Development

Schmiedestraße 5
15745  Wildau

Phone +49 3375 2152-280

Fax +49 3375 2152-282

Mathias Köhler

Contact Press / Media

Dr. Mathias Köhler

Head of working group | Structural Testing and Analytics

Schmiedestraße 5
15745  Wildau

Phone +49 3375 2152-278

Fax +49 3375 2152-282

Sebastian Steffen

Contact Press / Media

Dr. Sebastian Steffen

Head of department | Semi-finished Components

Schmiedestraße 5
15745  Wildau

Phone +49 3375 2152-246

Fax +49 3375 2152-282

Polymeric Materials and Composites PYCO

TAILORED MATERIALS

DESIGNS AND MANUFACTURING TECHNOLOGIES