Research Center STEX

Department Sustainable Fiber-Plastic Composites

The department of sustainable fiber-plastic composites is dedicated to the practice-oriented development of innovative technologies and systems. In close cooperation with industry partners, we focus on cutting-edge topics relating to the circular economy of fiber-reinforced composites. Our research includes SEAM 3D printing, towpreg, circular medical technology, crash and structural calculations and automatic non-destructive testing. We also focus on automated preform production and the creation of life cycle assessments (LCA). Our aim is to develop sustainable and efficient solutions for industry and thus contribute to technological progress.

SEAM 3D printing

Large-format, resilient plastic components (e.g. made of fiber-reinforced PA6, PA11, PP, PC, PEI) can be produced efficiently at high process speeds using the SEAM technique. Component dimensions of up to 1.6 x 1.2 x 0.8 m or 2 x 1.7 x 0.3 m and output rates of up to 15 kg/h are possible. The use of hybrid machines allows components to be subsequently processed by machining.

Video: Interview on ultra-fast 3D printing

Further Information

Circular economy

Resource conservation and environmental protection offer new value chains. It is important to keep materials in the cycle for as long as possible! Whether business models for the circular economy, evaluation of end-of-life components, reuse & repair of fiber composite and hybrid structures or recycling thereof, Fraunhofer IWU is the ideal partner. We attach great importance to automation and digitalization in order to ensure an optimal economic and ecological balance.

Automated preforming of fiber-reinforced semi-finished products

The use of pre-impregnated semi-finished fiber products can achieve significant time savings and cost advantages in today's composite production. Whether coiled, pultruded or hybrid and special technologies such as continuous filament 3D printing, the Fraunhofer IWU provides semi-finished product solutions for a wide range of applications through extensive developments.

Direct impregnation with thermoplastic matrix

More than 60% of medical devices are only used once. Innovative, circular strategies for closing material cycles involving medical device manufacturers, hospitals and recycling companies are therefore necessary. The Fraunhofer IWU supports you in developing a circular strategy. From design for recycling and reuse to efficient collection and recycling processes including sterilization, material flow analysis, processing and ecological evaluation.

Integration of Smart Textiles

Environmental life cycle assessments are nowadays an important part of being able to present and evaluate the environmental impact of products, processes and services. All environmental impacts, from production to disposal, are listed and evaluated. It serves as a decision-making aid in the development process, taking into account current and desired environmental aspects.

3D-printed textiles

Functional textile surfaces can be created using 3D printing. Usually, soft elastic plastic, e.g. thermoplastic elastomers, are used to print local structures or even flat areas on the textile. High form- and material-fit adhesion between textile and plastic can be achieved. The technology dis use for local reinforcements/wear protection as well as designs and lettering.

Crash and structural calculation

Lightweight construction potential, a wide range of possible uses and high energy absorption capacity for crash applications - these are the characteristics of fiber-reinforced plastic composites. In order to achieve optimum material utilization, the complex material behaviour must be precisely mapped at the design stage. Thanks to our many years of experience in the field of simulation, our focus is on crash- and load-path-compatible structural designs for fiber-reinforced composites in the automotive, railway and aerospace sectors.

Automated non-destructive testing

The NDT system developed by Fraunhofer IWU makes it possible to automatically test any fiber-reinforced plastic components measuring up to 2 x 1 x 1 m without CAD data. Collaborating robots, state-of-the-art measuring devices for 3D, thermographic and ultrasound examinations, automated path planning and measuring device control enable time-saving tests to be carried out. The data obtained can also be evaluated.

Automatic preform production

The production of endless, thickness-variable thermoplastic profiles and components such as hat and omega profiles is made possible by the integration unit developed at the Fraunhofer IWU. Thermoplastic materials on rolls are fixed at up to 400 °C and cut to size, for example to produce different cross-sections. Reduced process costs and time are a major advantage of this system.

Mobile lightweight robot

Constructed from lightweight materials such as carbon and aluminum, equipped with the latest high-performance drive technology and simple operation, the mobile robot developed by Fraunhofer IWU offers ideal conditions for the unmanned execution of a wide range of tasks. These include the mobile, non-destructive inspection of large-area FRP structures, plastic welding processes and the inspection of pipes and tunnels, both underwater and overhead.

Contact us

Contact to the STEX Research Centre

Reichenhainer Str. 88

09126 Chemnitz

Phone +49 371 5397-1020

Send email