B E T R I E B S F E S T I G K E I T , S Y S T E M Z U V E R L Ä S S I G K E I T , A D A P T R O N I K , K U N S T S T O F F E S T R U C T U R A L D U R A B I L I T Y , S Y S T E M R E L I A B I L I T Y , S M A R T S T R U C T U R E S , P L A S T I C S Jahresbericht 2020Annual report

I N H A L T Index 2020 im Überblick. 2020 at a glance. E I N B L I C K E | I N S I G H T S 4 Resilient. Nachhaltig. Digital. 9 Kuratorium. 10 Das Fraunhofer LBF in Zahlen 2020. 4 Resilient. Sustainable. Digital. 9 Board of trustees. 10 Fraunhofer LBF in numbers 2020. F O R S C H U N G M I T S Y S T E M ! | S Y S T E M A T I C R E S E A R C H ! 12 Leistungsfelder. 14 Digital Engineering. 20 Smart Solutions. 26 Reliability Design. 32 Circular Economy. 38 Ultra Lightweight Design. 44 Future Mobility. 12 Areas of Expertise. 14 Digital Engineering. 20 Smart Solutions. 26 Reliability Design. 32 Circular Economy. 38 Ultra Lightweight Design. 44 Future Mobility. F O R S C H U N G S B E R E I C H E | R E S E A R C H D I V I S I O N S 50 Betriebsfestigkeit. 52 Adaptronik. 54 Kunststoffe. E I N B L I C K E | I N S I G H T S 56 LBF Management Team. 58 Allianzen und Netzwerke. 50 Structural Durability. 52 Smart Structures. 54 Plastics. 56 LBF management team. 58 Alliances and networks. Impressum. | Editorial notes. Herausgeber | Publisher Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF, Bartningstraße 47, 64289 Darmstadt, Telefon: +49 6151 705-0, info@lbf.fraunhofer.de, www.lbf.fraunhofer.de Institutsleitung | Director of institute Prof. Dr.-Ing. Tobias Melz Redaktion | Editor Heiko Hahnenwald Koordination | Coordination Anke Zeidler-Finsel Konzeption | Conception Fraunhofer LBF, Technologiemarketing und Kommunikation Design/Konzeption | Design/conception www.gute-botschafter.de Druck | Printing www.halternerdruckerei.com Fotografie | Photography LBF-Archiv, Ursula Raapke, Katrin Binner, Piotr Banczerowski, Fraunhofer IVI, Fraunhofer IIS, BPW Gruppe, AdobeStock (jirsak, royyimzy_B, kras99, issaronow, Quardia Inc, OceanProd, Ints, vegefox.com, kv_san, Oleshko Artem) © Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF, Darmstadt, April 2021 Alle Rechte, insbesondere das Recht der Vervielfältigung und Verbreitung sowie der Übersetzung, vorbehalten. 3

Resilient. Nachhaltig. Digital. Resilient. Sustainable. Digital. Batteriegehäuse: Leicht, sicher, serientauglich. Battery housing: Lightweight, safe, and suita­ ble for series production. Sehr geehrte Kunden und Partner des Fraunhofer LBF! Wir alle haben 2020 als besonders kräftezehrendes Jahr erlebt. Viele Menschen standen im beruflichen und im privaten Umfeld vor großen Herausforderungen. Mit be- sonderer Wucht wurden die ausgeprägten Wechselwir- kungen und Abhängigkeiten unserer modernen Lebens- welt verdeutlicht. Gleichzeitig wurde die Wichtigkeit eines Perspektiv- und Kurswechsels im Kontext von Resilienz, Nachhaltigkeit und Klimaschutz sowie Mobili- tät und Digitalisierung unterstrichen, die Bedeutung der gemeinsamen Aufgabe und Verantwortung klar betont. Neben allen Schwierigkeiten und Herausforderungen lassen sich aber auch spannende Chancen erkennen. Mich hat beeindruckt, welche Ideen für Veränderungen und Optionen im Großen wie im Kleinen in kurzer Zeit entstanden sind, wie aufmerksam und verantwortungs- voll zusammengearbeitet wurde und wie engagiert und pragmatisch innovative Lösungen an so vielen Stellen umgesetzt wurden – all das im Spannungsfeld des Schutzes der Gesundheit und der Beherrschung wirt- schaftlicher Implikationen. Dabei haben sich nicht nur etablierte Beziehungen bewährt, sondern es sind spannende neue Partnerschaften entstanden. Als industrienah ausgerichtetes Institut haben wir die großen Unsicherheiten, Sorgen und Herausforderungen unserer Kunden deutlich miterlebt. Und wir stehen fest an der Seite unserer Partner. Gemeinsam mit Ihnen haben wir Veränderungsbedarfe herausgearbeitet, zeitliche und inhaltliche Entwicklungsperspektiven abgeglichen, Inno - va tionsthemen priorisiert, Forschungskapazitäten justiert und wichtige Zukunftsprojekte vorbereitet und gestartet. Dies war sehr konstruktiv und wertvoll, es hat die ver- trauensvolle Achse weiter gestärkt. Ich bin außerordent- lich zuversichtlich, dass hieraus auch zukünftig eine sehr positive gemeinsame Entwicklung resultiert. Vor diesem Hintergrund entwickelt das Fraunhofer LBF seine Forschungsausrichtung weiter: Durch ein umfassen- des Verständnis von Prozessen und Wechselwirkungen – von der Gestaltung über die Realisierung und Nutzung bis zur Verwertung - helfen wir unseren Kunden damit bestmöglich, effiziente und sicher zuverlässige Produkt­ innovationen zu schaffen. Dabei konzentrieren wir uns auf die Ebene Material, Bauteil und System und bauen konse- quent unsere virtuellen, physischen und cyberphysischen Entwicklungs- und Bewertungsmethoden weiter aus. So verankern wir die Themen Resilienz, Nachhaltigkeit und Digitali sierung noch fester in unserem Portfolio. In unseren FuE-Projekten erarbeiten wir kontinuierlich neue Lösungen hinsichtlich der Entwick lung effizienter Entwurfs­, Simulations- und Absicherungswerkzeuge. Gestaltung, Bewertung und Modellierung von Prozessen für zuver- lässige Produkte, Beherrschung von Unsicherheiten entlang der Wertschöpfungskette sowie nachhaltige Lösungen für Kunststoffe, deren Recycling und bioba- siertem Aufbau, sind einige Beispiele. »Im Fraunhofer LBF entwickeln wir konsequent virtuelle, reale und cyberphysische Methoden weiter.« Wir haben uns das Ziel gesetzt, unsere Projekte und FuE-Leistungen konsequent marktorientiert auszurichten. Im Zuge dessen haben wir diese im aktuellen Jahresbericht in sechs Clustern gebündelt: Ultra Lightweight Design, Digital Engineering, Smart Solutions, Circular Economy, Future Mobility Research und Reliability Design. Entlang dieser Themencluster präsentieren wir Ihnen Ergebnisse ausgewählter Forschungsprojekte und wie diese unsere Kunden in der Mobilität, dem Maschinen- und Anlagenbau, der Kunststoffchemie und der Energie- sowie der Medizintechnik unterstützen. 5

Produktentwicklung/Bauteilauslegung Probenprüfung Mechanik Morphologie Rheologie CAD Spritzgieß- simulation Mapping Struktursimulation Lebensdauer Polymer Lifecycle Digitalisierung der Bauteilauslegungsprozesse für kurzfaserverstärkte Materialien. Digitization of component design processes for short fiber reinforced materials. Dear customers and partners of Fraunhofer LBF! 2020 was an incredibly strenuous year for us all. Many people faced major challenges in their professional and private lives. This revealed the deep interactions and inter- dependencies that shape the modern world in which we live, in a truly profound way. At the same time, it under- scored the importance of a change of perspective and course in the context of resilience, sustainability and cli- mate protection, as well as mobility and digitization, and clearly emphasized the significance of our common task and responsibility. However, alongside all the difficulties and challenges, exciting opportunities are being revealed. I have been impressed by the ideas for change and options, both large and small, that have emerged in a short time, how thoughtfully and responsibly people have worked together, and the committed and pragmatic way in which innovative solutions have been implemented in so many places – all while balancing the need to protect health and deal with economic implications. In this con- text, not only have established relationships stood the test of time, but exciting new partnerships have emerged. As an industry-oriented institute, we have of course wit- nessed the major uncertainties, concerns and challenges facing our customers. Indeed, we are standing firmly by our partners. Together with you, we have identified needs for change, aligned development opportunities in terms of timing and content, prioritized innovation topics and adapted research capacities, while preparing and laun- ching important projects for the future. This was very constructive and valuable – it further strengthened the trust between us. I am extremely confident that this will continue to result in very positive joint development in the future. Against this background, Fraunhofer LBF is continuing to develop its research focus: Using a comprehensive under- standing of processes and interactions – from design and implementation to use and recycling – we can provide our customers with the best possible help in creating efficient, safe and reliable product innovations. In doing so, we focus on the material, component and system level, con- sistently expanding our virtual, physical and cyber- physical development and evaluation methods. In this way, we are enshrining the themes of resilience, sustai na bility and digitization even more firmly in our port folio. In our R&D projects, we are continuously working on new solutions for developing efficient design, simu la tion and validation tools. Examples of this include the design, evaluation and modeling of processes for reliable products; the manage- ment of uncertainties along value chains; as well as sustainable solutions for plastics, their recycling and bio-based construction. “ At Fraunhofer LBF, we are making consistent progress in the development of virtual, real and cyber-physical methods.” We have set ourselves the goal of consistently aligning our projects and R&D services with the market. In doing this, we have combined them into six clusters within the current annual report: Ultra Lightweight Design, Digital Engineering, Smart Solutions, Circular Economy, Future Mobility Research and Reliability Design. Through these thematic clusters, we present you with the results of selected research projects and how they support our customers in mobility, mechanical and plant engineering, plastics chemistry and energy – as well as medical technology. 7

Kuratorium. Board of trustees. Vielen Dank! Sven Hamann (Vorsitzender) Robert Bosch GmbH, Renningen Prof. Dr. Mathias Glasmacher Diehl Stiftung & Co. KG, Nürnberg Florian Sprenger Dr. Ing. h.c. F. Porsche AG, Weissach Prof. Dr. Tim Hosenfeldt Schaeffler Technologies AG & Co. KG, Herzogenaurach Dr. Patrick Kim Bridge Builder, Kassel Rainer Salomon FOSTA – Forschungs- vereinigung Stahlanwendung e. V., Düsseldorf Dr. Kurt Pötter BMW Group, München MinR Norbert Michael Weber Bundesministerium der Verteidigung, Bonn Dr. Xenia Beyrich-Graf BASF SE, Ludwigshafen Dr. Ferdinand Hollmann Deutsche Forschungs- gemeinschaft, Bonn Dr. Peter Klose Valantic Supply Chain Excellence AG Dr. Ralf Kunkel Audi AG, Ingolstadt MinR’in Dr. Ulrike Mattig Hessisches Ministerium für Wissenschaft und Kunst, Wiesbaden Prof. Dr. Matthias Oechsner Technische Universität Darmstadt, Darmstadt 9

28,06 Millionen € Betriebshaushalt 32,2 % Wirtschaftserträge 13,9 % Rest 16,3 % EU 69,7 % Deutschland 20,5 % Öffentliche Erträge 24,2 % EU 1,3 % Sonstige 75,8 % Bund / Länder Betriebshaushalt 2020 I Operational budget [T €] Wirtschaftserträge Öffentliche Erträge Sonstige Erträge Interne Programme 9.048 5.765 373 Investitionen | Investments [T €] 3.670 aus institutioneller Förderung Institutionelle Förderung (Grufi) 9.204 Projekinvestitionen Summe | total 28.060 Summe | total 1.483 297 1.780 1 2 0 2 . 3 0 . 4 2 : s u t a t S 1 1 1 1

Leistungsfelder. Areas of Expertise. In unseren zentralen Leistungsfeldern erarbeiten wir innovative Lösungen für die Märkte von morgen, maßgeschneidert für unsere Kunden, systematisch vom Produktdesign bis zur Nachweisführung. In our areas of expertise, we systematically develop innovative solutions for the markets of tomorrow, from product design to proof testing, tailor-made for our customers. Digital Engineering: Die Produktentwicklung der Zukunft ist schnell, effizient, flexibel und digital. Am Fraunhofer LBF erarbeiten wir innovative Modellierungs- und Simulationslösungen von der Produktentstehung über die Nutzung bis zum End of Life. Digital Engineering: The product development of the future is fast, efficient, flexible and digital. In Fraunhofer LBF, we develop innovative modeling and simulation solutions from product creation and use to the end of life. Smart Solutions: In einem Umfeld, in dem Wert - schöpfungs ketten, Produktionsabläufe sowie Materialien und Bauteile bis an die Grenzen optimiert werden, ent wickeln wir intelligente Monitoring lösungen, um Schäden zu vermeiden, Wartungs maß nahmen zu optimieren und ungeplante Ausfälle zu minimieren. Smart Solutions: In an environment in which value chains, production flows, as well as materials and components are being optimized as much as possible, our researchers are developing smart monitoring systems to prevent damage, limit the need for main- tenance and minimize unplanned failures. Reliability Design: Die zuverlässige Funktion ist seit jeher eine Grundanforderung an Produkte. Wir entwickeln neue Methoden und Werkzeuge zur zuverlässigen Gestaltung von Materialien, Bauteilen und Systemen. Reliability Design: Reliable functioning has always been a key requirement for products. We continuously develop new methods and tools for the reliable design of materials, components and systems. Circular Economy: Kunststoffmaterialien besitzen ein großes weiteres Einsatzpotenzial. Damit dieses auch umweltschonend genutzt werden kann, arbeiten wir intensiv an Lösungen für ressourceneffiziente, nach­ haltige und biobasierte Kunststoffe. Circular Economy: Plastic materials have a large amount of untapped potential applications. We are intensively working on solutions for resource­efficient, sustainable and bio-based plastics so that they can be used in an environmentally friendly way. Ultra Lightweight Design: Leichtbau ist eine der wichtigsten Querschnitts technologien der Zukunft. Mit unserer Forschung gehen wir bewusst immer stärker an die Grenzen des Machbaren und entwickeln eigenschafts- optimierte, besonders leichte Strukturlösungen. Ultra Lightweight Design: Lightweight construction is one of the most important cross-sectional technologies of the future. With our research, we are consciously pushing the boundaries of what is possible ever further and developing particularly lightweight structural solutions. Future Mobility: Nachhaltig, vernetzt und autonom wird die Mobilität in der Zukunft sein. Mit unseren Kernkompetenzen im Leichtbau, dem Reliabilty Design und den Werkzeugen des Digital Engineering gestalten wir innovative Fahrzeugkonzepte. Future Mobility: Sustainable, networked and autonomous – these features are the hallmarks of future mobility. With our core competencies in Lightweight Construction, Reliability Design and Digital Engineering tools, we design innovative vehicle concepts. 1 3

Industrial value creation is characterized by ever shorter product life cycles and, at the same time, increasing pro duct diversity – sometimes with individually tailored pro perties – as well as the distributed development, rea lization and use of products. In addition, there are increasing requirements for sustainability and resource efficiency, as well as increased functional complexity of systems in different operating and usage scenarios. Against this background, product development pro- cesses are coming under increasing pressure in terms of efficiency, costs and flexibility, e.g. due to the reduction of available prototype systems or the increasing need for early decision-making and safeguarding processes to accompany development. Alternative development tools and realistic digital models are therefore needed to ensure that the requirements for quality, safety and reliability of the products can still be met. The aim here is to increase the predictive quality of the actual component and system behavior through suitable modeling in such a way that, among other things, the number of prototype systems can be reduced and physical validations can be supplemented and optimized by virtual analyses. In the Digital Engineering area of expertise, research- ers are developing new methods and, where necessary, customized tools that aim to virtually map development, safeguarding and validation processes. For instance, innovative modeling and simulation solutions allow for extended functional properties in plastic components and in mechanical systems to be considered as early on as the early design and realization process. At the same time, usage data from practice, production and operation are integrated for validated modeling and simulation. This allows influences, stresses or damage at the material, component and overall system level to be realistically digitally reproduced. In this way, the number of possible variants for the later realization of a product can be reduced to a minimum at an early stage of the design and development process. In conjunction with new cyber-physical methods and tools, it is also possible to implement end-to-end validation of products and product functions at the component level through out the development process. Increasingly scarce development capacities can be utilized efficient by supplementing and replacing specific experimental analyses, as well as through numerical methods and validation processes. “We develop the tools to make your digital product development efficient.” 1 5 1 5

KUNSTSTOFFALTERUNG, LEBENSDAUER PLASTIC AGING, SERVICE LIFE Lebensdauerabschätzung für Kunststoffe durch die Verknüpfung von Experiment und Modellierung. Kunststoffe sind im Alltag wechselnden Umwelt- einflüssen und komplexen Belastungskollektiven ausgesetzt. Für Industriepartner werden auf die jeweilige Anwendung zugeschnittene Prüfmethoden und Prüfprotokolle entwickelt. Diese Kenntnisse fließen in Software­Tools ein. Durch die Kopplung der Modelle und deren Para- metrisierung durch Alterungsexperimente können bereits in der Entwicklungsphase praxisnahe Belastungsszenarien modelliert und bewertet werden. Das verkürzt Entwicklungszeiten und mindert Ausfall- und Haftungsrisiken. Estimating the service life of plastics by linking experimentation and modeling. Plastic components are exposed to changing environmental influences and complex load collectives while in operation. Test methods and test protocols tailored to the relevant application being are developed for industrial partners. This knowledge has been incorporated into software tools for predicting property changes. By linking the models and parameterizing them through aging experiments, practical load scenarios can be modeled and evaluated as early as the development phase. This makes it possible to shorten development times and reduce the risk of failure and incurring liability during use. LEICHTBAU, DIGITALER ZWILLING LIGHTWEIGHTING, DIGITAL TWIN Automatische FE-Berechnungen eines digitalen parametrisierten Elektromotor berechnungsmodells. Die Elektromobilität gilt als Schlüssel zur klima- freundlichen Mobilität und als wichtiger Baustein der Energiewende. Das Projekt »fabulous« beschäftigt sich mit funktionsintegrierten Antriebsbauteilen aus Hochleistungs-Verbund- stoffen. Neben der Prozess- und Materialent- wicklung wird ein Leichtbau-Radnabenmotor entwickelt. Ziel sind Effizienzsteigerung sowie die Gewichtsreduktion von Radnabenmotoren durch die Substitution von Metallkomponenten mittels neu entwickelter Hochleistungsmaterialien. Automatic FE calculations of a digital parametric electric motor calculation model. Electromobility is regarded as the key to climate- friendly mobility and as an important building block for energy transition. The “fabulous” project is concerned with functionally integrated drive components made of high- performance composites. As well as the process and material development, a lightweight wheel hub motor is being developed. The aim of the project is to increase the efficiency and reduce the weight of wheel hub motors by substituting metal compo- nents with newly-developed high-performance materials. ERSATZVERSUCH, BETRIEBSFESTIGKEITSERPROBUNG Teilstrukturen realitätsnah prüfen mit einstellbaren Anbindungselementen Ausführliche Informationen auf Seite 18. SUBSTITUTIONAL TEST, STRUCTURAL DURABILITY TEST Realistic testing of substructures with adjustable connection elements. See Page 18 for detailed information. 1 7

Realisierter Prüfstand mit Nach­ bildung der z- und x-Steifigkeit, sowie der Biegesteifigkeit um y. Realized testing bench with simulation of z­ and x­stiffness, as well as bending stiffness around y. Detaillierte Informationen online: www.lbf.fraunhofer.de/ teilstrukturen Detailed information online: www.lbf.fraunhofer.de/ partial-structures Successful product development ends with validation of the product’s suitability. An often time-consuming aspect of this is the experimental verification of service life under operating conditions. The weaknesses identified here are only detected at a very late stage, which can lead to considerable project delays. At Fraunhofer LBF, methodological competencies in service life as- sessment have been combined with technologies in vibration engineering and further developed. This enables product validation to be successfully completed more quickly. Adjustable interfaces that replace the surrounding structure Using the example of a vehicle floor of an electric vehicle, which accommodates the battery cells, the integration and demonstration of a workflow for developing and re- alizing a realistic test could be shown. This floor structure must endure large mechanical loads, such as the twisting of the bodywork that results from driving over a pothole. In the demonstration testing bench, a realistic component load was generated for this purpose. However, only one of the six segments of the floor structure is available for testing, as opposed to the entire body. Model-based digital process for developing the substitutional test A numerical model of the overall structure is used to determine the strain that would occur in the test speci- men during operation. In addition to the external load, this is also influenced by the stiffness of the surrounding structure, which is simulated in the test setup by bearing points with adjustable stiffness. This is followed by a digital model of the test setup with adjustable boundary conditions. Here, there is also a cost­benefit analysis. Adjustable mounts and programmable interfaces* The use of adjustable mounts and programmable interfaces allows for the parameters to be varied quickly without modification work. It is only necessary to set the desired stiffness on the mount or load the numerical tar- get model of the vehicle to be simulated. The stiffnesses of adjustable mount and mHIL interface are continuously adjustable between 0.4 kN / mm and “rigid” (> 60 kN/mm). FE­Analyse zur Ermitt­ lung der mechanischen Randbedingungen für den Prüfling. FE analysis to determine the mechanical boundary conditions for the test specimen. Schnittstelle Significant acceleration of product validation processes Testing substructures with adjustable stiffness boundary conditions makes it possible to validate components and assemblies earlier in the product development process. It is also possible to test larger quantities at the substruc- ture level, which leads to better statistical validation of service life. The adjustability of the equivalent stiffness elements also enables easy testing of the assembly for different variants of the surrounding structure, such as different body versions. Overall, the adjustable connect- ing elements therefore enable successful completion of product validation at a faster pace. ANSPRECHPARTNER I CONTACT Dr. Volker Landersheim +49 6151 705-475 volker.landersheim@lbf.fraunhofer.de Jan Hansmann +49 6151 705-8366 jan.hansmann@lbf.fraunhofer.de 1 9

Intelligent sensor technology for the targeted collection and assessment of large amounts of data, increasing networking, function distribution and real-time, cross- system data communication, as well as function enhance - ment and mechatronization, are all drivers of digitiza- tion in modern products. Artificial intelligence and data-based services not only enable process chains in production to be analyzed, simplified and optimized. In fact, they also allow for structural monitoring that is adapted to current environmental and operating conditions, as well as actively influencing factors such as the vibration characteristics of machines and vehicles. In the Smart Solutions area of expertise, scientists are researching and developing hardware and software solutions, based, among other things, on digital enginee- ring modeling approaches, for smart maintenance appli - cations, for predicting and preventing unplanned machine and system failures, and for increasing technical availability. Another topic is the targeted influencing of the vibration­ related properties of structures in mobile systems such as vehicles and in machines and systems. In both cases, machine learning methods are used for the advanced “Innovative materials and AI-based solutions for intelligent condition moni toring and noise control.” analysis of growing volumes of data, in conjunction with intelligent sensors and sensor networks, as well as integrated actuator technology. In this context, work with so-called metamaterials is going even further. These have high potential for the structurally-integrated influencing and adjustment of qualities such as acoustic or structural dynamic properties for the purpose of the reduction or alternative adjustment undesirable or harmful vibrations and sound radiation. The linking of methods established in relation to reliability as well as in vibration and materials engineering with new data-driven, digital approaches that the work aims to achieve is moreover an important building block for the develop- ment and realization of intelligent lightweight structures. 2 1

SCHWINGFESTIGKEIT, INTELLIGENTE SCHRAUBE FATIGUE STRENGTH, SMART SCREW CONNECTION Drahtlose, energieautarke Fernüber- wachung von Schraubverbindungen. Wireless, energy-autonomous remote monitoring of screw connections. Schraubenverbindungen, insbesondere bei sicher heitsrelevanten Verbindungen, müssen eine zuverlässige Befestigung sicherstellen und sind regelmäßig zu inspizieren. Durch die perma- nente energieautarke und drahtlose Fernüber- wachung können Veränderungen der Belastung von komplexen, verschraubten Strukturen früh- zeitig erkannt, bewertet und somit die Zuverläs- sigkeit der Strukturen wesentlich erhöht werden (digitale Vernetzung von Systemen). Offshore- Strukturen, Windenergie anlagen, Brücken, Gebäudefassaden u. a. können profitieren. Screw connections must ensure reliable fastening, especially for connections that help ensure safety, and must be inspected regularly. Permanent energy-autonomous and wireless remote moni- toring makes it possible to detect changes in the load placed on complex screw-fastened structures that are relevant to safety at an early stage, evaluate the changes and thus significantly increase the reliability of such structures (through the digital networking of systems). Offshore structures, wind turbines, bridges, building facades e.g. may benefit. METALLKISSEN, SCHWINGUNGSTILGER METAL CUSHION, VIBRATION ABSORBER Weich wie Gummi, beständig wie Metall. As soft as rubber, as durable as metal. Metallkissen sind Formteile aus einem Draht- gestrick. Ihre elastischen Eigenschaften sind mit denen von Elastomerbauteilen vergleichbar. Sie bestehen vollständig aus Metall, sind hin - sichtlich Temperatur und Medieneinflüssen sehr beständig und daher für Applikationen geeig- net, in denen Elastomere aufgrund inhärenter Limitationen nicht eingesetzt werden können. Das Fraunhofer LBF befasst sich mit der expe ri - mentellen Analyse und numerischen Model- lierung der dynamischen Eigenschaften von Metallkissen in einem weiten Frequenzbereich. Hochgradig flexible Lösungen für individuelle Fragestellungen sind das Ergebnis. Metal cushions are molded parts made of a woven wire mesh which have elastic properties and are therefore comparable to elastomeric components. Given that they are made entirely of metal, they are very resistant with regard to temperature and the influence of various media, making them particularly well-suited to applications in which elastomers cannot be used due to their inherent limitations. Fraunhofer LBF has put great commitment into the experimental analysis and numerical modeling of the dynamic properties of metal cushions in a wide frequency range. This has resulted in highly­flexible and customized solutions for individual problems. PASSIVE SCHWINGUNGSMINDERUNG Vibroakustische Metamaterialien zur Beeinflussung von Akustik und Strukturdynamik. Ausführliche Informationen auf Seite 24. PASSIVE VIBRATION REDUCTION MEASURES Vibroacoustic metamaterials for influencing acoustics and structural dynamics. See Page 24 for detailed information. 2 3

Vibroakustische Metamate rialien können Körperschall mindern. Vibroacoustic metamaterials are designed to reduce structure­ borne noise. Detaillierte Informationen online: www.lbf.fraunhofer.de/ vibroakustik Detailed information online: www.lbf.fraunhofer.de/ vibroacoustics The “MetaVib” project involves researching vibroacoustic metamaterials and developing these as an innovative vibration reduction approach. They are suitable for application in a wide range of industries, e.g. mechanical engineering, the automotive sector or aerospace. At Fraunhofer LBF, work is being carried out in the areas of conceptual design, numerical and experimental characterization to close the research gap in systematic design processes. How do vibroacoustic metamaterials work? Research into vibroacoustic metamaterials is currently being carried out across the world. With their help, the amplitudes of harmful structural vibrations and noise can be reduced to a depth and broadband that is practically impossible to achieve using conventional measures. These metamaterials are made of periodically arranged passive or active local resonators applied to the component that is to be influenced. The local resonators are tuned to the addressed resonant frequency and placed on the basic structure at intervals smaller than half the wavelength of the frequency to be influenced. In this frequency range, so-called “stopbands” – areas in which no wave propagation is possible – are then created in the transfer function. Virtual development process for specific applications Currently, the design and manufacturing of vibroacoustic metamaterials is mostly done without a sufficiently systematic approach or consideration of economical manufacturing processes. These issues are addressed in the internal Fraunhofer PREPARE project “MetaVib”. The cross-institutional research teams develop the design, simulation and manufacturing of passive and active vibro acoustic metamaterials. The methodology developed is validated using two application-oriented demonstrators: A vehicle door is used for structure- borne noise reduction and on a silencer is used for influencing acoustics. Furthermore, in the case of acoustics, active vibroacoustic metamaterial concepts are considered and prototypically implemented. At Fraunhofer LBF, the focus is on an application-orien ted virtual development process, which includes the develop- ment of concepts and their numerical preliminary designs. The design process is independent of the application, and, in “MetaVib” its effectiveness is demonstrated on a vehicle door. Concepts involving vibroacoustic metama- terials for defined frequency ranges consisting of metal or plastic taken into consideration. The concepts are designed in detail using numerical routines. The know- ledge gained is implemented in the form of a toolbox that enables the design and optimization of structures as vibroacoustic metamaterials at different levels of detail. Funding: Fraunhofer “PREPARE” internal program, partner institutes: Fraunhofer IBP, Fraunhofer IDMT, Fraunhofer IFAM, Fraunhofer IWU ANSPRECHPARTNER I CONTACT Heiko Atzrodt +49 6151 705-349 heiko.atzrodt@lbf.fraunhofer.de 2 5

“Our research makes reliable products possible by using reliable processes.” comprehensive manner, so that validation and assurance processes can be continuously moved forward into the early design process. In the spirit of “design to reliability”, digital engineering solutions are linked with new design and simulation methods. Based on realistic application data in relation to typical mechanical, climatic, electrical and combined multiphysical loads, tools and processes are being developed that take into account the reliable design of structures as early as the design stage. In this way, “safety margins”, which, in many cases, are still common today, can be reduced further and further in the future while maintaining or increasing the reliability of materials, components and products, thus enabling modern solutions that push the limits of what is feasible. Ever lighter material solutions and structures on the one hand and ever more complex products and systems on the other are shaping product development in many industrial sectors. At the same time, however, the require ments regarding the reliability of such systems are increasing. After all, malfunctions and failures in this context can quickly have critical economic, ecological or health effects. The Reliability Design area of expertise represents a key scientific focus of Fraunhofer LBF. This is not just a matter of ensuring the service life of materials, components and products. Rather, the research and development activities in this area of expertise are aimed at understanding and describing all phases of product development, use and application along with their interactions, in an increasingly Detaillierte Informationen online: www.lbf.fraunhofer.de/ reliability-design Detailed information online: www.lbf.fraunhofer.de/ reliability-design-en 2 7

DLC-BESCHICHTUNGEN, ELASTOMERE, DICHTUNGEN, TRIBOLOGIE DLC COATINGS, ELASTOMERS, SEALS, TRIBOLOGY Elastomere robuster machen mit Diamond Like Carbon (DLC) Beschichtungen. Making elastomers more robust with diamond-like carbon (DLC) coatings. Elastomerbauteile stehen unter großer mecha- nischer Belastung. Gerade im dynamischen Bereich werden diese aufgrund von Abrieb mechanisch abgenutzt, was zu Fehlfunktionen führen kann. Ein Beispiel dafür sind Radialwel- lendichtringe (RWDR). Ihre Dichtlippe läuft auf der Oberfläche einer sich drehenden Welle und wird meist von einem Federring radial auf die Wellenoberfläche gedrückt. Die Dichtigkeit der Dichtlippe ist entscheidend für die Funktion der RWDR. Eine Schutzummantelung mit spezieller Rezeptur aus dem Fraunhofer LBF kann die tribologischen Eigenschaften der Dichtlippe verbessern und somit die Langlebigkeit des Produkts gewährleisten. Elastomeric components are subject to great mechanical strain. They are subject to mechani- cal wear due to abrasion, particularly in dynamic situations, which can lead to malfunctions. Radial shaft sealing rings are a typical example of this. Their sealing lip runs along the surface of a rotating shaft and is usually pressed radially onto the shaft surface by a spring washer. The tightness of the sealing lip is crucial for the functioning of the radial shaft sealing ring. A protective coating with a special formulation from Fraunhofer LBF can improve the tribolo- gical properties of the sealing lip and thus ensure the longevity of the product. ADDITIVE FERTIGUNG, LEICHTBAU Zuverlässiges Bauteildesign durch realitätsnahe Bean spru- chungssimulationen und inno- vative Bemessungskonzepte. Ausführliche Informationen auf Seite 30. ADDITIVE MANUFACTURING, LIGHTWEIGHTING Reliable component design using realistic strain simulations and innovative design concepts. See Page 30 for detailed information. 2 9

Um die Zuverlässigkeit additiv gefertigter Bauteile besser gestalten zu können, hat das Fraunhofer LBF die »AM FATIGUE LABS« eingerichtet. In order to better design the reliability of additively manufactured components, Fraunhofer LBF has set up the “AM FATIGUE LABS”. Additive manufacturing offers unprecedented op- portunities for the sustainable lightweight design of components. At the same time, it presents those responsible for components with major challenges when it comes to reliably exploiting the strength potential of additively manufactured components. The process-related material properties as well as the impact of defects differ significantly from conventional manufacturing processes. The AM FATIGUE LABS are creating new types of application safety by developing dedicated design concepts and investigation methods for additively manufactured components. t = 2 , 5 m m Kantur Hatching g n u t h c i r u a B P u l v e ri c r a u h t u f t r n a g g s - Schweißraupen Gefüge einer PBF­LB/M Struktur. Microstructure of a PBF­LB/M component. In the AM FATIGUE LABS, realistic simulations are de- veloped that show reliable design characteristics for the design of additively manufactured components. They also ensure design validation by taking the influence of all relevant process parameters into account. Special- ly-developed load simulators increase the precision and reproducibility of the measurements. This insight into the cyclic material and component behavior would be almost impossible using classical testing methods. To also be able to exploit the advantages of additive manufacturing for safety-relevant components, in terms of lightweight construction, many challenges have to be met in the alternating field of component geometry, manufac- turing, operational stresses and environmental influences. Detaillierte Informationen online: www.lbf.fraunhofer.de/ bemessungskonzepte Detailed information online: www.lbf.fraunhofer.de/ fatigue-labs Local phenomena drive component fatigue The realization that component fatigue is driven by local phenomena is becoming increasingly important, espe ci- ally for additively manufactured components. The new levels of freedom in component development require a new design concept to be able to leverage the potential of this manufacturing technology for cyclically stressed, safety-relevant components as well. On the one hand, the manufacturing process induces geometric defects in the form of pores, inclusions or rough surfaces; on the other hand, the very limited local heating leads to the formation of significant property gradients. Here, factors including the direction of construction and the design of the required support structures also play a significant role in the formation of the material microstructure, thereby affecting the local properties, including the defect distribution. Optical strain measurement produces new insights In the AM FATIGUE LABS, the Fraunhofer LBF team uses a range of optical strain sensors whose measure ment signals have the required real-time c apability. In this way, strain control is made possible, for example, in component areas that are relevant for failure. At the same time, the researchers derive information about the local damage mechanism from the synchronous-load measurement of local strain fields. This information can be used for com­ po nent optimization. What is more, it can also be used to increase material utilization by taking defect-oriented material behavior into account in early design phases. ANSPRECHPARTNER I CONTACT Dr. Rainer Wagener +49 6151 705-444 rainer.wagener@lbf.fraunhofer.de Matthias Hell +49 6151 705-8468 matthias.hell@lbf.fraunhofer.de 3 1

Plastics are an integral part of our everyday lives. They offer the widest range of options in material technology solutions for a large number of applications. A wide range of properties can be imprinted in a targeted manner: Foodstuffs are hygienically packaged in a safe and durable manner using plastics. As insulating and sealing materials with special fire protection properties, they are a modern building material. As engineering plastics, they offer effective and efficient functional features and lightweight construction potential in primary and secondary compo- nents – often being shaped in a highly complex manner with defined insulating, vibration damping, sensory or actuator functions. Yet while their extraordinarily positive technical properties cannot be denied, plastics are increasingly the subject of critical discussion. They are emblematic of modern environmental problems, in the form of microplastics or the pollution of the oceans, which we help to reduce through our research work. In the Circular Economy area of expertise, Fraunhofer LBF scientists are working on sustainable, durable and environmentally compatible plastics solutions, from the molecule, formulation and chemical-physical characteriza- tion to synthesis and validation, from use to the “end of life” and recycling – thereby transforming linear processes into circular ones. The particular strength of LBF is its profound expertise in the additivation of plastics in order to adapt highly­specific material properties. Thus, biopoly- mers made from renewable raw materials can also be ad- justed and upgraded for demanding technical applications in terms of their service life, degradation or performance. On the other hand, innovative additive systems allow for enhanced processability and improved end properties for recycled material. What is more, additive systems can significantly expand the possibilities for material recycling of conventional polymers in terms of upcycling. Another field of research involves the development of bioadditives as substitutes for commercial systems which, in terms of quality and performance, achieve comparable properties to conventional additives and in some cases significantly surpass them, e.g. for the weather resistance or flame retardancy of polymers. “We develop sustainable, recyclable and bio-based plastic solutions for a green future!” 3 3

LEICHTBAUVERFAHREN, BIOBASIERTE KUNSTSTOFFE, ORGANOBLECHE, NATURFASERVERSTÄRKTE, INTELLIGENTE BATTERIESYSTEME Naturfaser-verstärkte biobasierte Kunst- stoffe für Leichtbaulösungen am Beispiel eines Li-Ionen-Batterie-Gehäuses. LIGHTWEIGHT PROCESS, BIO-BASED PLASTICS, ORGANIC SHEETS, NATURAL-FIBER-REINFORCED PLASTICS, SMART BATTERY SYSTEMS Natural-fiber-reinforced bio-based plastics for lightweight solutions, using the example of Li-ion battery housing. Im Projekt »BIOBATTERY« entwickeln Forschende aus dem Fraunhofer LBF in Zusammenarbeit mit einem Batteriehersteller integrierte Funktions- gehäuse aus naturkurzfaserverstärkten biobasier- ten Kunststoffen. Am Beispiel von Batteriemo- dulen zeigen sie Standardisierungen für unter- schiedliche Performance-Anwendungen im Automobil- und Maschinenbau auf. Ziel ist eine effiziente und kostengünstige Serienfertigung für Leichtbauteile. As part of the “BIOBATTERY” project, researchers from Fraunhofer LBF, in cooperation with a battery manufacturer, are developing integrated functional housings made from natural fiber reinforced bio-based plastics. Using the example of battery modules, they are demonstrating standardizations for a range of performance applications in the automotive and mechanical engineering industries. The goal is the efficient and cost-effective series manufacturing of lightweight components. ADDITIVE, BIOKUNSTSTOFFE, NACHHALTIGKEIT Circular Plastics Economy: Biokunststoffe für den technischen Einsatz. Ausführliche Informationen auf Seite 36. ADDITIVES, BIO-PLASTICS, SUSTAINABILITY Circular plastics economy: Bio-plastics for technical use. See Page 36 for detailed information. 3 5

Recycling Recycling- additive Verarbeitungs- stabilisatoren Produktion Circular plastics economy. Nukleierungs- mittel Hydrolyse- stabilistatioren Nutzungsdauer Detaillierte Informationen online: www.lbf.fraunhofer.de/ biokunststoffe Detailed information online: www.lbf.fraunhofer.de/ bioplastics Society and political actors are calling for a reduction in dependence on petroleum-based raw materials and more sustainable production, e.g. through reductions in CO2 emissions. In this con- text, bio-based plastics are becoming increasingly important for industry. Currently, the main areas of application for high-quality bio-based plastics have mostly been based on single-use or short- term use (such as packaging or disposable cutlery). Compostable bioplastics are an alternative to fossil-based plastics here, but the potential of high-quality bio-based polymers cannot be fully exploited. The raw material must be modified by specific additives until it can meet the highest de- mands for long-term stability, rendering it usable for technical applications. PLA + innovative Additivsysteme Mindestanforderungen Verlängerter Lebenszyklus PLA n e t f a h c s n e g e a i r e t a M l i Verarbeitung Lebenszyklus Recycling Neue, im Fraunhofer LBF entwickelte Additivsyteme verlängern den Lebenszyklus von Biokunststoffen. New additive systems developed at Fraunhofer LBF extend the life cycle of bioplastics. Extended life cycle In the development of plastic compounds with long-term stability, various parts of the product life cycle must be considered. This starts with the compounding of the addi- tive systems into the base plastic, the subsequent shaping (e.g. injection molding), the application and the recycling. From a circular point of view, thermal recycling has to be ruled out and mechanical recycling has to be undertaken. In a further processing step, additive systems are added to restore mechanical properties and to achieve long- term stabilization, thus making the compound suitable for long-term uses. Molecular weight degradation and the associated loss of mechanical properties in bioplastics are primarily caused by hydrolytic cleavage of the polymer chain. To evaluate the stabilizing effect of various additives or additive systems, these are incorporated into bioplastics and the compounds produced are subjected to water storage. To accelerate aging, this is carried out at ele- vated temperature (60 °C), while the melt viscosity of the plastic is determined as an indicator of the molecular weight change. Using additives to achieve long-term stability Up until now, the long-term properties of hydrolysis-sen- sitive (bio)plastics have been improved through the use of hydrolysis inhibitors. Investigations at the Fraunhofer LBF into stability against degradation have shown that the use of innovative additive systems provides an advantage over state-of-the-art stabilizers in terms of hydrolysis resistance. With the newly developed stabilizer system, the MVR value shows an increase in flowability of about 30 percent after two weeks of water storage. This is compared to a 300 percent increase for the state-of-the- art stabilizer and an increase of > 5000 percent for the unstabilized PLA. The additive systems developed at Fraunhofer LBF can also increase the continuous service temperature and shorten the cycle time, opening up new areas of application, e.g. in the electrical or automotive industries. ANSPRECHPARTNERIN I CONTACT Dr. Elke Metzsch-Zilligen +49 6151 705-8609 elke.metzsch-zilligen@lbf.fraunhofer.de 3 7

Lightweighting has long since ceased to be a “technical niche solution” for aircraft and innovative sports vehicles. Rather, affordable lightweight solutions for the best possible mass and energy efficiency in all mobile systems – such as in the production and operation of products – are key to achieving climate policy goals in vehicle manufacturing, mechanical and plant engineering, ener- gy and the construction industry. Without lightweight construction, the possibility of commercially successful products, such as those in electromobility, would be- come less and less, perhaps rendering them impossible. What is more, successful, safe lightweight construction requires comprehensive expertise in reliability and structural durability. smart structures and develops novel solutions from function-integrated, intelligent lightweight construction, always taking into account the reliability, sustainability and affordability of the technical product solution. Scientists conduct interdisciplinary research and develop solutions, for example, for functionalized polymers, functionally integrated fiber composite systems, mono­ and multi-material systems, numerical and experimental methods of reliability and durability assessment of light- weight solutions, and the use of integrated sensors and actuators for the monitoring and property optimization of structures. In the Ultra Lightweight Design area of expertise, LBF is pushing the limits of what is possible even further. This is based on holistic knowledge at the level of mate- rials, components and systems technology. In addition, methods of material construction as well as those of constructive and systemic lightweight construction are combined. Fraunhofer LBF pools its expertise in the research areas of plastics, structural durability and “With our research, we are pushing the boundaries of what is possible and developing radically lightweight, property- optimized structural solutions.” 3 9

AGILER MULTICOPTER, EVTOL-GLIDER, TRANSPORT- DROHNE, INTELLIGENTE BATTERIESYSTEME Fraunhofer Leitprojekt ALBACOPTER®: Experimental Vertical Take-Off and Landing Glider. Durch die Erschließung der dritten Dimension des urbanen Verkehrsraums im Sinne einer Urban Air Mobility (UAM) bieten sich Lösungs- ansätze zur logistischen Flexibilisierung und zur Überwindung nachteiliger Folgen eines stetig wachsenden Verkehrs aufkommens. Im Rahmen des Fraunhofer­Leitprojekts ALBACOPTER® soll bis Ende 2024 eine fliegende Experimentalplattform mit der VTOL­Fähigkeit eines Multicopters und den aerodynamischen Vorzügen eines Gleiters entwickelt und für Testflüge zugelassen werden. Mehrere Fraunhofer­Institute (ICT, IEM, IOSB, LBF, IMS) bringen unter Leitung des Fraunhofer IVI ihre Kompetenzen und Technologien in das ambitionierte Forschungsvorhaben ein. Weitere www.albacopter.fraunhofer.de AGILE MULTICOPTER, EVTOL GLIDER, TRANSPORT DRONE, SMART BATTERY SYSTEMS Fraunhofer ALBACOPTER® lighthouse project: Experimental Vertical Take-Off and Landing Glider. Developing the third dimension of urban traffic space, in terms of Urban Air Mobility (UAM), opens up solutions for increasing logistical flexibility and overcoming the negative conse- quences of a constantly-increasing volume of traffic. As part of the Fraunhofer ALBACOPTER® lighthouse project, six institutes under the leadership of Fraunhofer IVI are developing an innovative drone concept that will make a sig- nificant contribution to electrified autonomous, pollution­free (peri­)urban air traffic. LASTENFAHRRAD, LEICHTBAURAHMEN, TUBULAR ENERGY SYSTEM TES, NUTZLASTÜBERWACHUNG, TRANSPORTBOXENTWICKLUNG, LEICHTBAUFELGEN LastenLeichtBauFahrrad »L-LBF«. Ausführliche Informationen auf Seite 42. CARGO BIKE, LIGHTWEIGHT FRAME, TUBULAR ENERGY SYSTEM TES, PAYLOAD MONITORING, TRANSPORT BOX DEVELOPMENT, LIGHTWEIGHT RIMS Lightweight “L-LBF” cargo bike. See Page 42 for detailed information. Graphic:Fraunhofer IVI 4 1

Ultraleichte Transportbox mit Crash­Strukturen. Ultralight cargo box with crash structures. Detaillierte Informationen online: www.lbf.fraunhofer.de/l-lbf Detailed information online: www.lbf.fraunhofer.de/ lightweight-cargo-bike Cargo bikes represent an important alternative to cars in urban traffic. They are environmentally aware, flexible, fast and climate-friendly. Young families, craftsperson and delivery services use cargo bikes on the road. Fraunhofer LBF is deve- loping sustainable, safe and reliable solutions for the next generation of cargo bikes. Commercially-available cargo bikes were used for the initial condition. One aim of the project was to clarify specific opportunities for saving mass on the cargo bike in a practical way. In the case of a tricycle with a Bakfiet structure, redesigning the frame, along with a change of material from a steel to an aluminum alloy, resulted in the weight of the front end being reduced by approximately 40 percent, or more than 40 kilograms. At the heart of this redesigned frame is a multi-curved aluminum support tube into which a tubular battery system developed for this bike, also known as the Tubular Energy System (TES), is integrated in a way that is theft-proof manner and keeps it well-protected from external weather conditions. The battery system originally mounted on the outside of the bike frame provided the rider with a capacity of 500 Wh, while the innovative TES contains 80 Li-ion cells and provides a capacity of 1000 Wh. Sensory connecting elements were also developed as part of this project. These are located between the front-end frame and the transport box and serve to ensure a secure connection that can be monitored. The force sensor modules contain capacitive sensor layer systems based on dielectric elastomers. Four of the sensor modules, which are only 8 millimeters thick, are mounted as connecting elements in the corner areas of the transport box and provide the option of continuously checking the payload, its position and its distribution in the box during the ride. In addition, their high level of sensitivity enables them to measure road conditions, from which further business models can be derived. The sensor data is shown to the rider on a display. The transport box is an important element in relation to the load. To demonstrate a particularly lightweight solution, a box is being built with additively manufactured bionic structures in combination with carbon fiber rein­ forced plastics. Crash structures can be integrated for transporting sensitive loads. Moreover, a box made of combinations of biomaterials, e.g. meadow grass with flax fibers, bonded with biopolymer, was constructed as an ecologically sustainable solution. Due to their thermal-isolating properties, these boxes are ideal for transporting things such as hot food. The Long John cargo bike also features an active system to reduce handlebar wobble. With the integrated controlled sensor-actuator system, both ride comfort and ride safety are significantly increased, especially over longer distances. This further increases the acceptance and benefits of this mode of transport. ANSPRECHPARTNERIN I CONTACT Dr. Saskia Biehl +49 6151 705-282 saskia.biehl@lbf.fraunhofer.de Sensormodul Sensor module 4 3

“With our methods, we are also supporting and shaping the implementation of future innovative vehicle concepts.” Mobility is undergoing a sustainable transformation process. It is increasingly understood as a networked system of different mobility solutions and operator models. The demands on mobile resource efficiency have once again massively increased, not least due to criticism regarding increasing pressures in relation to climate change and the decarbonization required. They make it necessary to develop new drive technologies, lighter construction methods and alternative mobility concepts. The progressive electrification of mobile sys- tems, the intermodality of modes of transport and the intro duction of increasingly automated driving functions are an essential building block in the movement toward future mobility, from a technical and organizational perspective. The same applies to the increased use and development of new small and micro vehicles in the field of private transport, such as pedelecs, cargo bikes, e-scooters – or increasingly drones. The topic of shared mobility also offers technical challenges ranging from smart digital solutions, app developments, and distributed functions to material technology – especially because, in this context, it is necessary to master entirely new usage scenarios. New future mobility solutions whether on land, by road or rail; on water or in the air – must function safely and relia bly, while, at the same time, being cost-effective and efficient to implement and operate. Yet they must also meet the ever-increasing requirements in terms of the number of mobility carriers, individualization and sustainability in the passenger vehicle, commercial vehicle and special vehicle sectors. The consistent focus on a thermoplastic and thermoplastics-based approach has led to questions being asked about suitable lightweight solutions, reliable system design, intelligent structural and monitoring functions, sustainable materials and even the use of biomaterials. In this context, the Future Mobility area of expertise at Fraunhofer LBF combines the work of the other areas of expertise in relation to their application in mobility solutions, e.g. cyber-physical methods for the validation of new mobility technologies that accompany the development of alternative drive concepts, component-integrated battery systems or innovative ultra-lightweight construction solutions. One focus of the work is electromobility, using both battery-electric and fuel cell systems. 4 5

NUTZFAHRZEUG, ANTRIEB, DEFOSSILISIERUNG CO2-Minderung durch Energieeffizienz im leichten Verteilerverkehr. COMMERCIAL VEHICLE, DRIVE, DEFOSSILIZATION CO2 reduction through energy efficient light distribution transport. Logistik und Transport werden deutlich dominiert vom Straßengüterverkehr und verursachen mehr als 5,5 Prozent der weltweiten CO2-Emissionen. Ab 2025 müssen die in der Europäischen Union neu zugelassenen Nutzfahrzeuge spezifische Emissionsziele erreichen; bei zu hohen Fahrzeug- emissionen werden Strafzahlungen von bis zu 65.000 € pro verkauftem Fahrzeug fällig. Speziell für Fahrzeuge des leichten Verteilerverkehrs bietet sich das im Fraunhofer LBF patentierte Konzept des generator-elektrischen Antriebs an. Es verknüpft in besonderer Weise Energieeffizienz und Wirtschaftlichkeit. Logistics and transport are clearly dominated by road freight transport and account for more than 5.5 percent of global CO2 emissions. From 2025, new commercial vehicles registered in the European Union will have to meet specific emission targets; if vehicle emissions are too high, penalties of up to € 65,000 per vehicle sold will be imposed. The generator-electric drive concept patented at Fraunhofer LBF is especially suitable for light distribution vehicles. It combines energy efficiency and economy in a special way. AUTONOMES FAHREN, SENSORNETZWERK, DIGITALER ZWILLING, KÖNIGSZAPFEN Zustandsüberwachung auto- matisiert fahrender Fahrzeuge. Ausführliche Informationen auf Seite 48. AUTONOMOUS DRIVING, SENSOR NETWORK, DIGITAL TWIN, KINGPIN Condition monitoring of self-driving vehicles. See Page 48 for detailed information. 4 7

MKS­Modell der Achsen im Offline-Zwilling IdenT-Trailer. MBS model of the axles in the offline twin IdenT- trailer. Detaillierte Informationen online: www.lbf.fraunhofer.de/ zustandsueberwachung Detailed information online: www.lbf.fraunhofer.de/ condition-monitoring Drivers of conventional vehicles steer them safely from their starting point to their destination, while keeping an eye on the vehicle’s condition. But who monitors the condition of autonomous vehicles when the driver is no longer there? As part of the “IdenT“ research project, researchers are developing a concept for determining the condi- tion of trailer components relating to driving-dy- namics and relevant to safety, as well of the trailer dynamics and the surrounding environment. The automated driving functions of the tractor can use this information to optimize driving tasks and make autonomous driving safe. Digital twin and sensor network support condition monitoring The “IdenT” system is built on a cloud-based data plat- form that regularly exchanges data between the trailer data network, digital online twin and digital offline twin. The latter serves to numerically simulate driving sequences relevant to structural durability and check the plausibility of measurement data, as well as data from an online twin. The central element of the offline twin is a detailed MBS model of a truck trailer in which specific model parameters are subjected to a regular update process using a variety of identification procedures. On the one hand, the aim is to identify time-variant behavior, for example, in the load, as well as wear or defects in chassis components, and to project these onto the simulation model. On the other hand, the numerical simulation of individual driving sequences determines the dynamic behavior of the trailer and thus the com- ponent internal loads, from which a prognosis of the condition regarding structural durability can be deduced. In “IdenT” trailers, a sensor network records what the human truck driver perceives through their eyes, ears and the sensation of driving. This provides the digital twins with relevant physical quantities for interpretation. The focus is on energy-saving sensor concepts that function economically and are highly-reliable when actually in ope- ration. For this purpose, the measurement data is already preprocessed in the sensor node, thereby reducing the data volume and minimizing the energy required for radio transmission. The expert teams at Fraunhofer LBF are also evaluating what minimum requirements need to be in place for sensor data quality to allow such a system to be built in a cost effective but reliable way. Sensory KingPin The KingPin is the trailer coupling that links the tractor and trailer. All forces that occur during braking, acceleration or cornering are transmitted through this element. “IdenT” involves mounting a unique high-precision force mea- suring device on the KingPin. This allows measurement data to be collected in the road test and compared with the digital twin so that these internal forces can be determined by models in the future. As mea- suring elements on the KingPin, the Fraunhofer specialists utilize a measurement platform that records all forces and moments that the pin is subject to. ANSPRECHPARTNER I CONTACT Riccardo Möller +49 6151 705-408 riccardo.moeller@lbf.fraunhofer.de Johannes Käsgen +49 6151 705-613 johannes.kaesgen@lbf.fraunhofer.de 4 9

Detaillierte Informationen online: www.lbf.fraunhofer.de/ betriebsfestigkeit Detailed information online: www.lbf.fraunhofer.de/ structural-durability Rüdiger Heim Bereichsleiter Betriebsfestigkeit und Systemzuverlässigkeit +49 6151 705-283 ruediger.heim@lbf.fraunhofer.de Structural Durability as one of the most powerful methods in lfetimeoriented design of components and structures forms the basis of our instituts research activities since it’s founding. The mobility industry, mechanical and plant engineering and renewable energies benefit from equally light and reliable products designed for the entire operating and utilization phase. In terms of structural durability, we have reached a historic milestone with the 8-step block program from Ernst Gaßner. Today, we combine state-of-the-art numerical, metrological and experimental methods of structural durability with a solution quality that meets our standards: “We create lightweight construction. Reliably.” Methods and procedures for the fatigue life oriented assessment of structures and proof of safety and struc- tural integrity are our core competencies. They can be found in successful products, in material and component innovations as well as in novel processes, such as in additive manufacturing. As part of digitalization, these core competencies within powerful instruments are supplemented by cyber-physical simulation and a description of cyclical material characteristics extending continuously from the LCF through the VHCF regime. “ To us, structural durability is the obligation to harness and shape the digitalization of engineering products!” With a strong focus on applicability, our research and work is dedicated to the fatigue life oriented design of safe components, assemblies and systems in road and railway vehicle construction as well as in shipping and aviation, but also in crane manufacturing and for wind turbines. Our two divisions are specialized in everything from the material to the complete structure and will support you expertly. Materials and Components • Structural durability of metallic materials and components under cyclic oscillation loading with constant and variable amplitude loading. • Development and application of numerical methods for component dimensioning with the consideration of manufacturing properties and surface post-treatment. • Efficient determination of the fatigue strength of components and statistical evaluation of Wöhler and Gaßner lines. • Adapted testing technology for low-load tests with high­precision, reproducible force and deflection specification. • Fatigue strength of materials and components under the influence of aggressive media, such as fuels, corrosive aqueous solutions or hydrogen. Assemblies and Systems • Characterization of rubber / metal components, determination of the structural durability. • Numerical elastomer models, assignment of quantitative data from the experiment. • Description of complex kinematics using multi-body simulation (MBS), construction and verification of such models up to the complete vehicle. • Derivation of time-lapse test programs for laboratory testing (basis: measured load-time series). • Multiaxial laboratory tests for assemblies / systems (load-bearing components, such as wheel-guiding and rotating chassis systems). • Design, development and implementation of customized testing scopes incl. construction of any necessary special test rigs. • Operational load simulation trials, ensuring the structural durability of assemblies / systems. 5 1

Dr. Sven Herold Bereichsleiter Adaptronik +49 6151 705-259 sven.herold@lbf.fraunhofer.de The research work in this area focuses on analyzing, influencing and optimizing the vibration behavior of components and structures as well as increasing the reliability of mechanical systems. To improve the system properties, we consider innovative passive and active structural measures in addition to lightweight construc- tion principles. We provide support during the feasibility study, design and implement prototypical customer- optimized solutions. We develop adapted tools for sys- tem design and assist during their transfer to commercial implementations. For this we develop and use modern methods of numerical and experimental structural and reliability analysis, structural dynamics and signal process- ing. Smart sensor and actuator systems and electronic subsystems are developed to implement reliable active structural solutions, and control technology solutions are derived from embedded systems. There exists an integrated design chain: metrological analysis, numerical methods for concept evaluation, design and simulation, production of prototype mechanical, electromechanical and electronic functional models, methods and tools for ensuring function and reliability in the laboratory and in field trials. “ We develop methods and processes for smart and reliable lightweighting structures for our customers.” Structural Dynamics and Vibration Technology • Structural dynamic analysis, design, evaluation of systems. • Vibration control, rotor dynamic, vibro-acoustic system optimization, passive and active measures. • Signal processing and control technology for active systems. • Development and application of modern numerical system simulation. • System development with rapid control prototyping and hardware-in-the-loop. • Analysis and assessment of the reliability of mecha- tronic components / systems. Experimental Analysis and Electromechanics • Modern methods of vibration measurement. • Metrological investigations, determination of operating loads / operating stresses, measured data analysis. • System identification (EMA, TPA, etc.). • Development, implementation, integration of application-optimized actuator and drive systems. • Application and integration of custom-matched sensors, development of energy self­sufficient intelligent sensor nodes and systems. • Electronic and embedded systems, autonomous structural analysis, damage detection. • Adapted Condition and Structural Health Monitoring Systems. 5 3

Detaillierte Informationen online: www.lbf.fraunhofer.de/ kunststoffe Detailed information online: www.lbf.fraunhofer.de/ plastics Prof. Dr. Rudolf Pfaendner Bereichsleiter Kunststoffe +49 6151 705-8605 rudolf.pfaendner@lbf.fraunhofer.de Only cutting-edge products with reliable and rapid access to innovative and high-performance materials can be offered competitively on the world market today. Tailored plastics, plastic additives, plastic composites and plastic processing technologies play a central role in meeting high global demands in the areas of mobility, energy, environ- ment, communication, health, nutrition and safety. Plas- tics enable tremendous savings in resources and energy as well as a wide variety of options in lightweight design. Particularly when they are fiber­reinforced, particle­filled, foamed or integrated into sandwich structures, plastics can withstand the highest degree of loading and absorb a great deal of energy. They can be supplemented with an additional range of functions such as protection from UV rays and the affects of weathering, reduced fire behavior, functions for the development of special optical properties, electric and thermal conductivity and with sensor and actuator functions. At the same time, increasing demands on sustainability require new solutions in terms of a circular economy and recycling or the development of bioplastics. All components relevant for the implementation of sophisticated plastic applications, running the scope from basic natural science disciplines such as chemistry and physics, material sciences and material technology in processing to expertise in analytics, testing and modeling, are united at a high level under one roof. The following three departments are complementary in their disciplines and methods. Polymer Processing and Component Design • Plastics processing: compounding, reactive extrusion and injection molding. • Processing of the material into the component, prediction of mechanical properties. • Interlinking of process- and material properties. • Material modeling: material behavior under high strain rates and with multiaxial loading. • Design and prototype production of conventional, fiberreinforced and function­integrated plastic components. Polymer Synthesis • Development of chemical syntheses for monomers, polymers, additives, reactive modifiers. • Technical synthesis optimization and upscaling. • Development and screening of thermosets. • Specific adjustment of interface and surface properties. Formulation Development and Durability • Development of additives for customized modification of properties, e. g. with regard to material safety, reliability, failure characteristics, sustainability, resource efficiency. • Materials analysis, polymer analysis and characterization. • Development of analytical techniques. • Kinetics of reactive processes. “ We develop long-lasting and safe plastics with improved recyclability as well as new technologies for an efficient circular economy.” 5 5

I N S T I T U T S L E I T U N G Management of the institute Institutsleiter Prof. Dr.-Ing. T. Melz tobias.melz@lbf.fraunhofer.de B E R E I C H K U N S T S T O F F E Plastics S T A B S S T E L L E N Staff sections Prof. Dr. rer. nat. R. Pfaendner +49 6151 705-8605 rudolf.pfaendner@lbf.fraunhofer.de Kunststoffverarbeitung und Bauteilauslegung Dr.-Ing. C. Beinert +49 6151 705-8735 christian.beinert@lbf.fraunhofer.de Polymersynthese Dr. Frank Schönberger +49 6151 705-8705 frank.schoenberger@lbf.fraunhofer.de Rezepturentwicklung und Dauerhaftigkeit Prof. Dr. rer. nat. R. Pfaendner +49 6151 705-8605 rudolf.pfaendner@lbf.fraunhofer.de A S S O Z I I E R T E S F A C H G E B I E T Associated department Systemzuverlässigkeit, Adaptronik und Maschinenakustik Prof. Dr.-Ing. T. Melz www.sam.tu-darmstadt.de Wissenschaftsmanangement Prof. Dr.-Ing. T. Bein +49 6151 705-463 thilo.bein@lbf.fraunhofer.de Ultraleichtbau Dr.-Ing. S. Biehl +49 6151 705-282 saskia.biehl@lbf.fraunhofer.de Wissenschaftlich-Technische Betriebsorganisation Dr. K. Burlon +49 6151 705-8899 konrad.burlon@lbf.fraunhofer.de Technologiemarketing und Kommunikation H. Hahnenwald +49 6151 705-8330 heiko.hahnenwald@lbf.fraunhofer.de Organisationsentwicklung I. Langer +49 6151 705-371 ilona.langer@lbf.fraunhofer.de Smart Digital Solutions Dr.-Ing. Ch. Thyes +49 6151 705-8228 christian.thyes@lbf.fraunhofer.de Arbeitsschutz R. Wirth +49 6151 705-332 reinhard.wirth@lbf.fraunhofer.de 5 7

Berlin Chemnitz Bremen Dortmund Oberhausen St. Augustin Frankfurt a. M. Hanau Wiesbaden Darmstadt Pfinztal Ettlingen Stuttgart Freiburg München 5 9