Lightweight technology is undoubtedly one of the most important future technologies for automotive, aircraft and machine manufacturing, as a result of both increasing environmental awareness and scarcity of resources. The Fraunhofer project group “Functional Lightweight Design” (FIL) of the Fraunhofer ICT carries out applied research in the area of lightweight design with an emphasis on composites. Continuous-fibre-reinforced composites offer, in comparison to steel or aluminium, not only the highest lightweight potential, but also a variety of functional advantages. Metal-composite hybrid structures also have a high potential in many application fields.

For this reason there is a wide interest in high-performance composites in southern Germany (Bavaria and Baden-Württemberg), especially due to the concentration of industrial companies from the aerospace, machine and automotive sectors. The FIL has an outstanding opportunity to become a central partner in a developing network for composite technologies in southern Germany, with a high potential for the acquisition of third-party-funded projects and a large and sustained partnership base. Emphasis will be placed on the automotive and machine manufacture. Aircraft applications will also be considered where a high potential for synergy is identified.

The new project group optimally complements the existing Fraunhofer institutes in terms of know-how and planned facilities. The focus will be placed on the following technologies: modular fibre placement, alternative, fast and energy-efficient curing processes (Quickstep), on-line injection and consolidation processes (pultrusion), intelligent hybrid design (CFRP-metal hybrid structures), on-line process monitoring and recycling. The topics “design for high performance composites” and “materials and component properties” will be comprehensively developed along with the technologies. All process developments will be accompanied by process simulation techniques to acquire a fundamental understanding of the physical mechanisms taking place while processing. From the theoretical knowledge and experimental experience obtained, the individual process steps will be optimised and interlinked, so that ultimately an automated manufacturing technique capable of high-volume production can be developed, with high industrialisation potential for diverse application fields and quantities of parts.