Projects

As part of the “OrganoFoam” joint research project, we developed bio-based foams for upholstered furniture and mattresses, which were evaluated and further processed by Friedrich Platt GmbH. The novel polyurethane flexible foams were produced in the laboratory in block form. They can be cut, bonded, and upholstered using existing equipment, while offering a level of comfort comparable to that of conventional upholstery foams. This creates a marketable alternative for manufacturers seeking to expand their product range toward sustainable furniture with an improved carbon footprint.

As digitalization advances in the context of Industry 4.0, there is a growing need for a high density of sensors integrated into machines and systems. In the DELIGHT project, the Fraunhofer LBF is developing an industrial manufacturing technology for elastomer sensors that can be integrated into load-bearing elastomer components such as machine bearings or couplings. The sensors are based on the patented capacitive DELTA-C® technology and can measure both static and dynamic forces. This makes it possible, for example, to monitor machines, detect overloads, and extend maintenance intervals.

Sustainable recycling management through artificial intelligence: Fraunhofer LBF is leading a work package in the K3I-Cycling innovation laboratory and is also contributing its many years of practical experience with plastic recyclates to other work packages.

The increasing automation of maritime systems is raising the bar for securing the AI components used in these systems. In the BMWE-funded “SIMAS” project, we are collaborating with TKMS and its TKMS ATLAS ELEKTRONIK segment, DNV, and FEV Etamax to develop a new methodology based on a risk-based approach. By integrating AI performance data into Bayesian networks, we are enabling a transparent safety assessment of autonomous maritime vessels.

Bross – Determining the Influence of Corrosive Loads and Local Defects on the Load-Bearing Capacity of Bronze Casting Materials: How can these various influences be taken into account in component design? The goal is to ensure reliable and failure-free operation of marine components - even when individual influencing factors vary.

Lithography is crucial for the manufacture of electronic semiconductors. New resists with high sensitivity and resolution are needed to increase component density and cope with mass production. With the IndiNaPoly project, Fraunhofer researchers aim to support the chemical industry in gaining a technological edge and tapping into new markets. Resist manufacturers are an important link in the semiconductor industry. Manufacturers of specialty polymers and semiconductors also benefit from the results.

“COOPERATE” demonstrates how innovative methods for material characterization and modeling make it possible to use bio-based thermoplastics even when their properties fall short of those of conventional materials. Simulation-based design led to the development of a sustainable suspension link with comparable performance. The methodology developed opens up new ways to select materials based on sustainability criteria while still producing durable components.

Recycled plastics make it difficult to manufacture high-quality plastic components due to impurities, inhomogeneities, and increased mold wear during injection molding. The ROBUST project is developing wear-resistant, optically textured mold coatings to improve surface quality and reduce scrap.

Lightweight high-voltage energy storage systems for electrified semi-trailers.