Structural composites

The structural composites group is concerned with the development and optimization of materials and processes for the manufacture of high-performance lightweight structures. The highest strengths in components can be achieved through the targeted use of continuous fibers.

Fully automated production cell for the production of hybrid thermoplastic structural components (MoPaHyb Project)
© Frauhofer ICT
Fully automated production cell for the production of hybrid thermoplastic structural components (MoPaHyb Project)

Material development

Integrated composite floor module
© Fraunhofer ICT
Integrated composite floor module

Many raw materials and semi-finished products can be used for the manufacture of fiber composite structures. We support our customers in the development or selection of the right matrix and fiber semi-finished products to achieve the best material properties and at the same time enable efficient manufacturing. We work with both thermoplastic and thermoset matrix systems using the available fiber types and production processes suitable for series production. Hybrid materials and their processing also play an important role.

Process development

Fiberforge - fully automated machine for the placement of unidirectional fiber reinforced thermoplast tapes (UD-Tapes)
© Fraunhofer ICT
Fiberforge - fully automated machine for the placement of unidirectional fiber reinforced thermoplast tapes (UD-Tapes)

Our large portfolio of manufacturing processes allows us to efficiently manufacture fiber composite structures on an industrial scale. Our expertise lies in the consideration of the entire process chain and the optimization or further development of individual processes to meet the required quality and production rate. One of our core competences is the validation of the manufacturing processes and the plant technology in an industrial environment, using our own facilities.

Benefit from our expertise

  • Production of samples for material characterization
  • Operating and manufacturing with customer molds with the RTM/HD RTM/wet molding process
  • Instrumented test stands to characterize the deformation behavior of dry and wet textile semi-finished products
  • Preforming: automation and optimization of the subprocess steps cutting, handling, draping, and trimming
  • RTM/HD RTM: reactive thermoset and thermoplastic processing with injection pressures of up to 200 bar
  • Industrialization of processes for epoxy resin systems, polyurethanes and caprolactam (in-situ polymerization)
  • Wet and prepeg compression: Characterization and further development of the molding processes and their derivatives
  • Tape laying on industrial scale, energy-efficient consolidation of fiber-reinforced semi-finished products
  • Automated reshaping or compression molding of thermoplastic and thermoset semi-finished products
  • Manufacture of profiles by pultrusion (classic and with injection
    chambers; with thermoset and thermoplastic material systems)
  • Process data acquisition and evaluation for documentation and simulative validation