Press releases

All organic substances, including plastics such as polypropylene (PP), undergo auto-oxidation in the presence of oxygen. This happens millions of times faster at the high temperatures of compounding and injection moulding. The result for PP is a degradation of the polymer chains, i.e. a reduction in molecular weight, which means that products made from these plastics can no longer be recycled. Antioxidants added during the manufacturing process slow down this degradation. Without these additives, many everyday objects could not be produced in a usable form. Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have further improved the rheological online tests so that the exact additives can be determined more quickly, and the costs optimised.

At a time when environmental sustainability is paramount, recyclates are of central importance in industry. Due to EU regulations and waste reduction targets, their use has increased significantly. However, a major challenge is to ensure that post-consumer recyclates meet safety standards, especially in terms of flame retardancy. Upgrading with effective halogen free flame retardants is essential. Teams of experts at the Fraunhofer Institute for Structural Durability and System Reliability LBF are working intensively on EU regulations and the need for halogen free flame retardancy in specific applications. The focus is on technical and strategic considerations from which many industries can benefit. Fraunhofer LBF will present the results at the Plastics Recycling Show Europe, Amsterdam, June 19-20, 2024, booth A22.

Lithium-ion batteries from electric vehicles lose their charging capacity during the use. Therefore, they are no longer suitable for vehicle operation from a ca-pacity loss of 20 percent, as the range and fast-charging capability are reduced. However, the remaining capacity of 80 percent is sufficient for a stationary storage application. In the CIRCULUS research project, several Lithium-ion trac-tion batteries already in use are being converted into a stationary storage sys-tem. The innovative lightweight design of the overall system ensures that the system can be dismantled according to type. This minimizes the sorting effort, resulting in high-quality material flows and thus implementing a functional and sustainable circular economy. Fraunhofer LBF will be presenting the results of the CIRCULUS research project at the Plastics Recycling Show Europe, Amster-dam, June 19-20, 2024, booth A22. Visitors will gain a comprehensive insight into Fraunhofer LBF's wide-ranging expertise in recyclates.

For the first time, the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE will present the topic ‘Sustainable Geosynthetics for Landscaping’ at ACHEMA 2024 alongside the topic ‘Advanced Recycling’. We cordially invite you to visit us at the trade fair in Frankfurt (Hall 6.0 – Research and Innovation | Booth D49).

The energy crisis, material shortages, lack of skilled workers and inflation are limiting the competitiveness of the German foundry industry. There is a great need to produce more efficiently and sustainably. In addition to digitalization, efficiency increases can be driven forward in particular through increased networking between those involved in the development process from industry and research. The international congress "InCeight Casting C8", from March 5 to 7, 2025 in Stockstadt, Germany, offers this interdisciplinary exchange of knowledge and interests for the third time with in-depth specialist presentations, workshops and panel discussions with the aim of learning from each other and thus remaining fit for the future.

With their high chemical and thermal resistance, metal cushions are a sensible alternative to elastomer components. The elasticity and damping of the wire mesh is based on the interaction of individual wire segments during deformation - a mechanism that is also reflected in the change in electrical properties. Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have harnessed this effect in the form of a new sensor concept. The new sensor technology can be integrated into existing systems in a cost-effective and space-neutral manner and directly detects vibrations and loads. Processes and bearing conditions can be monitored and dynamic bearing forces quantified with simple means. Applications in vehicle and mechanical engineering as well as in measurement and testing technology are conceivable

Challenges in the mechanical recycling of polycarbonate, opportunities for circular design in the automotive industry or the question of whether there are enough recyclates of appropriate quality for all users - these and more will be the topics of the sixth Forum Plastic Recyclates on March 13 and 14, 2024 in Darmstadt. This event offers expert knowledge on topics such as additivation and stabilization, analysis of recyclates, masterbatches and compounds as well as applications. The conference program and online registration are now available. The new #LBFDeepDive format answers questions from an exclusive group of participants.

In recent years there have been major changes in the life cycle testing of vehicles or individual components: Thanks to state-of-the-art testing technology today a few hours in the laboratory are sufficient for life cycle testing whereas previously test drives on the road taking a couple of weeks were necessary for this purpose. This development continues as the UC 16 -Users Conference on Biaxial Wheel/Hub Fatigue Testing on November 8th, 2023, in Darmstadt showed. More than 50 scientists and users from Europe and all around the world met at the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt. Thanks to a wide range of development and testing activities in the field of wheel testing and approval, the institute was able to establish itself as a technology leader. Today the testing technology is known and accepted on a worldwide basis. It has been established as the international standard for more safety in vehicle wheels construction. Besides it shortens the development times for new reliable and safety relevant products.

innovations for the technical supply industry Lightweight design makes products competitive and sustainable. Safety and reliable function must be guaranteed in the process. Promising new approaches for sustainable and efficient manufacturing processes with natural fiber-reinforced materials and the lightweight design potential through vibroacoustic metamaterials are shown by the exhibits from the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt at the "Highly advanced materials for a circular world", November, 14 to 16, 2023 in Jönköping/Sweden, ELMIA Subcontractor, Area: InnoDex, Hall D. The fair is a meeting point for decision makers, constructors and designers of the manufacturing industry in Northern Europe.

The use of recycled plastics is becoming increasingly popular due to its potential to reduce the environmental impact of plastic waste. However, the quality of recyclate materials significantly affects their application. With the exception of slightly damaged production waste, recycled plastics cannot be used in their original form. Usually, they are sorted, cleaned, and reprocessed to form usable granules. However, the recycled material's stability and processing ability for its intended application often require post-stabilization with suitable additives. Fraunhofer Institute of Structural Durabiity and System Reliability LBF has developed new formulations for enhance the quality of new recyclate films. At Plastics World Expo Europe, Essen, June 14-15, 2023, Booth C834, the researchers will give more information.