Reference projects of the Fraunhofer IST

A major step in all manufacturing processes is the surface-coating technology used on metals. By providing, amongst other things, protection against corrosion and wear, this has a decisive influence on the durability of components. Electrochemical or galvanic coating is thereby one of the most effective and cost-efficient surface-technology processes and occupies a very large share of the global market.

Human stem cells are a major source of hope for modern medicine, e.g. in regenerative medicine or as a cell model for pharmaceutical development, as human pluripotent stem cells can form all cells present in the human body. As part of the Fraunhofer-internal project “LabBag®, the three participating Fraunhofer institutes set themselves the goal of developing a closed surface-based “laboratory in a bag” for the cultivation of stem cells.

Aluminum surfaces are rapidly gaining in popularity. Also on materials of different types, such as plastics or other metals. Unfortunately, galvanic processes such as those used for copper, nickel or gold cannot be used for aluminum. In the “GALACTIF” project, funded by the BMBF, a process has been developed for the galvanic deposition of aluminum from so-called ionic liquids. For the first time ever, the process has been successfully transferred from the protective glove box to an open system which can be further developed on an industrial scale.

The partners in the project “Accelerating digital transformation in Europe by Intelligent NETwork automation – Automation of Network edge Infrastructure & Applications with aRtificiAl intelligence (AI-NET-ANIARA)” have set themselves the goal of developing solutions for automated, intelligent and cross-locational data exchange on the basis of concrete application scenarios from the field of sensors and manufacturing.

For the Mars2020 mission, bandpass filters were coated at 950 nm on the EOSS® using the MOCCA+® control software. The coating materials had to be stable against radiation and the filter had to withstand many cycles in the thermal vacuum test to simulate the days and years on Mars. They were coated onto quartz glass, which was cut to size and then bonded to the sensor.

Paper-based construction materials are an integral part of our everyday lives in the packaging industry. In order to utilise paper for these and new areas of application, the hydrophobic and antimicrobial properties of the material must be improved. In contrast to the processes currently used to modify the properties of paper, plasma polymerisation is to be used in the production process. As part of the BioPlas4Paper project, a novel plasma source concept was developed that can be used to create a reproducible process environment under atmospheric pressure that minimises the influence of ambient air and thus achieves homogeneous, reproducible coating results.

The increasing environmental awareness of the population requires a constant reduction of CO₂ across the entire value chain and over the entire product life cycle in order to achieve future climate targets. Innovative lightweight materials, material combinations, production technologies and multifunctional structures can make a significant contribution to achieving these goals and strengthening Germany as a centre of innovation. The project focuses on the development, optimisation and scaling of lightweight materials and technologies. In order to bring together the individual developments and evaluate them in terms of resource efficiency and lightweight construction, the battery system of an electric vehicle is chosen as an application example and demonstrator. These battery systems represent a central innovation component of sustainable mobility and are crucial for the competitiveness of electrically powered vehicles made in Germany.

For the redetermination of the Avogadro constant, an alternative, homogeneous SiO2 coating is being investigated in order to reduce measurement uncertainty and to be able to precisely determine the volume and mass of the sphere. With the aid of the atomic layer deposition (ALD) technique available at the Fraunhofer IST, it is possible to deposit stoichiometric SiO2 layers with a defined roughness and variable layer thickness whose properties meet the high requirements of the project. The SiO2 coatings developed at the Fraunhofer IST can be applied not only to spherical systems but also to surfaces of any complexity. Possible future fields of implementation range from optical applications, through semiconductors and electronics, and on to medical technology.

In the Demo-medVer project a mobile, decentralized system in modular configuration is being developed for the systemically integrated medical care of the population during a pandemic and in crisis and disaster situations. An essential component of decentralized care – and the focus of the work at the Fraunhofer IST – is the construction and testing of mobile systems to ensure an efficient and large-scale supply of disinfectants.

An additional tool was implemented into the broadband monitoring software MOCCA+® (Modular Optical Coating Control Application) as selectable option for thickness determination during optical interference filter deposition. The in situ measured transmittance spectra from an EOSS® (Enhanced Optical Sputtering System) coating machine in production environment could be successfully used.

With the objective of reducing the energy consumption as well as CO2, noise, and brake-dust emissions when using vehicle trailers, an innovative electric propulsion and control system has been developed for vehicle trailers within the framework of the “ev(electric vehicle)Trailer” project funded by the BMWi. The outstanding feature is the manufacturer-independent autonomous mode of operation of the evTrailer, which functions with any conventional tractor unit.

Toxic cobalt, which is mined under inhumane and environmentally destructive conditions, has long been an essential component of high-performance tools used to machine composite materials and light metals for wind power and electric vehicles, amongst other applications. »Green« cutting tools made from cobalt-free carbides and novel robust diamond and hard-material coating systems are to be developed and made available for key German industries.

In the 16 sub-Saharan African countries, at least 40% of the population corresponding to more than 130 million people have no access to safe water. The aim of the project was to research and develop an autonomous and decentralized ˝Made in Africa˝ water treatment system for rural and periurban areas which is highly efficient in the degradation of harmful pollutants and which is accepted by the rural communities.

PEM fuel cells have great potential for reducing greenhouse gas emissions, but are limited by uneconomical mass production. In the project ‘Development of production-process sequences for coated metallic bipolar plates for fuel cells of the highest quality and energy efficiency’, the Fraunhofer IST is working together with the Fraunhofer Institutes IWU and IWS on improving the properties, increasing the lifespan and developing and testing new production methods for metallic bipolar plates. This involves combining two coating approaches and forming processes.

Through the description of the following reference project, we would like to provide you with the opportunity to obtain your own impression of the potential of the various diffusion treatments. In the process, you will gain an insight into the specific problem and the challenges encountered, the solutions pursued by the Fraunhofer IST, the findings obtained, and the consequent benefits resulting from and beyond the project.

Seal-less rolling bearings that can be used under media lubrication possess a high potential for utilization in energy-efficient and resource-saving applications. Under these highly tribocorrosive conditions, standard rolling-bearing materials can only be used to a very limited extent. Within the framework of the POSEIDON II project, cost-effective novel steels are optimized by means of edge-layer treatments using adapted low-temperature plasma-diffusion treatment.

Climate change and the associated extreme weather conditions combined with the expanding human population are causing severe permanent or temporary water stress in many regions of the world. The joint ICON project WASTEC, conducted by Fraunhofer and Stellenbosch University, aims to develop strategies for addressing the serious threats to water demand and quality within the two broad themes of the desalination and re-use of water.

Energy imports into Germany covered around 74 percent of the country’s primary energy consumption in 2019 and are dominated by fossil fuels such as hard coal. As a result of the energy transition, the seaport location of Wilhelmshaven will have to undergo a transformation process in record time, thereby developing into a hub for low-carbon and renewable energy sources such as hydrogen (energy hub). The Fraunhofer IST is supporting this process as a scientific partner through its expertise in the field of energy storage and systems.

Metallized plastic components are used in the automotive industry in order to furnish lightweight and inexpensive plastics – such as ABS – with a high-quality surface. Galvanic plastic metallization, however, requires a chemical pre-treatment which will be banned in the near future due to the health hazards of the thereby utilized chromium(VI) compound. In the Fraunhofer-internal project “REAKOLA”, carried out in collaboration with the ILT, a laser-based process was developed which does not require chemical pre-treatment of the plastic surface and which will enable REACH-compliant galvanic metallization in the future.

Carbon-fiber-reinforced plastic (CFRP) is a magical material in aerospace: super-lightweight and extremely mechanically resilient. In its original state it is, unfortunately, neither electrically conductive nor solderable. In a joint project with Airbus DS, a process was developed in order to metallize CFRP and consequently make it electrically conductive and solderable. The resulting product was then used to coat CFRP waveguides which, as antennas for the ESA Sentinel 1 mission, fly around the Earth in low earth orbit.

Solid-state batteries are a promising concept for the further development of conventional lithium-ion batteries. By using solid electrolytes instead of liquid electrolytes, there is the potential for solid-state batteries to offer higher storage capacities, shorter charging times and greater safety in the long term. The FestBatt competence cluster works in an interdisciplinary manner on the production, optimization, processing and upscaling of materials for the new generation batteries.

In the SE.MA.KI project, a fully coordinated production system with standardized interfaces is being planned that allows a modular structure and an exchange of technologies depending on the particular application. In this blog post, Dr. Torben Seemann provides an insight into the project.

The goal of the ZESS as a Fraunhofer Project Center is to bring next-generation mobile and stationary energy storage systems to industrial maturity. In the field of mobile lithium solid-state batteries, ZESS will be developed into a unique national competence center that utilizes an interdisciplinary approach to develop innovative solutions for the entire value chain. Through its participation, Fraunhofer IST supports the further development of energy storage technologies.

Die Transformation zur Elektromobilität gilt als wichtiger Baustein zum Erreichen einer klimaneutralen Mobilität bis spätestens 2050. Für Elektrofahrzeuge ist die Karosserie nach der Batterie der größte Faktor für CO2-Emissionen. Das Konsortium des Leitprojektes »FutureCarProduction« entwickelt daher ganzheitliche Lösungsansätze für die Bewertung neuer Karosseriekonzepte der Automobilindustrie.

Due to the current resource- and environmentally-intensive battery production, there is a need for uniform and robust recycling and production systems as well as the use of secondary materials to close material cycles. The aim of the greenBatt competence cluster is to develop, design and apply innovative technologies, methods and tools for an energy- and material-efficient battery life cycle and closed material cycle.

How can economic, social and ecologically sustainable structural change be implemented in the former Helmstedt mining area? How can existing jobs be safeguarded in the region and new jobs created? What innovations are necessary if agricultural enterprises in the region are to be strengthened in the long term? In order to answer these questions and to not only reinforce local change in the areas of technology and services, resource efficiency and sustainable digital agriculture but to also increase value creation in the region, the Fraunhofer IST is working together with the Fraunhofer IKTS and in close cooperation with Wirtschaftsregion Helmstedt GmbH on the development and establishment of an innovation center for measures which promote the transfer of knowledge and technology

Integrating high-performance solar cells directly into the vehicle roof enables both charging of the battery when the vehicle is parked and significant relief of the on-board network whilst driving. Due to the limited surface area available, solar modules with the highest possible efficiency are required for this application. They must also be manufactured cost-effectively, as well as fulfil visual design and geometric shaping requirements.

In the evaluative research project HySecunda, nine Fraunhofer institutes are pooling their expertise and working on practice-oriented, scalable technological and capacitive solutions for a market ramp-up of green hydrogen in the entire SADC region (Southern African Development Community). The focus is thereby being directed at the three key areas of “Education and training”, “Certification and market for green hydrogen and market development” and “Technologies for fundamental research”.

The Salzgitter Hydrogen Campus is to be supported by the city, state, industry and research partners and intends to create and secure long-term added value and employment in the region. With this, long-term sustainable business models, market-ready products, an industrial hydrogen infrastructure, and a training platform for specialists and managers are to be developed and implemented.

Researchers at the Fraunhofer IST in Braunschweig have developed a process with which they can not only produce transparent, conductive – and consequently heatable – films. Their surface films also provide a further decisive advantage: The outer film is of low emissivity. It therefore ensures that the windshield cools down much more slowly. This prevents condensation from forming. The windshield remains dry and ice-free.