Reference projects of the Fraunhofer IST

Within the framework of the EU-funded project FAST – Functionally Graded Additive Manufacturing Scaffolds by Hybrid Manufacturing (GA 685825), processes were developed with which, through the combination of additive manufacturing and plasma technology, so-called “scaffolds” made from organic-inorganic hybrid material can be manufactured as bone-replacement products for regenerative medicine. Through the utilization of 3D printing, patient-individualized fabrication is possible.

The MOCCA+® (Modular Optical Coating Control Application) software can calculate coating thickness during the running coating process for an interference filter on the basis of optical spectra and can achieve a completely automated process by linking it to the system control. It has been transferred from the institutional research environment to production systems and expanded taking into account the associated requirements.

The Fraunhofer IST demonstrator greenhouse provides a research platform for modern cultivation methods – such as hydroponics – with which systems and components with film and surface-technology solutions can be developed and tested under realistic conditions. As a result, current challenges concerning product quality, pest control, and resource minimization can be addressed.

The comprehensive provision of medical care presents a major challenge, particularly in rural regions of Africa. The Fraunhofer Institute for Surface Engineering and Thin Films IST is therefore working in collaboration with the Fraunhofer Institute for Solar Energy Systems ISE and the Stellenbosch University in South Africa on the development of a mobile healthcare platform with which even the most remote areas can be reached.

At the Fraunhofer IST, atmospheric pressure plasma processes and the corresponding equipment are being developed which offer the possibility of functionalizing plastic surfaces under a defined atmosphere. With the equipment available, it is possible to impart specific chemical functionalizations to the surfaces. These can be, for example, nitrogen-containing groups generated by plasma treatment in nitrogen-hydrogen mixtures or ammonia. The production of functionalizations on the basis of layers with carboxylate or epoxide groups is, however, also possible through the utilization of suitable precursors such as maleic anhydride or glycidyl methacrylate.

The aim of the battery cell production competence cluster is to improve the battery cell production processes and their influence on cell properties and product development costs, and to further develop it for new battery generations. This is intended to lay the scientific foundation for the establishment and sustainable further development of internationally leading and competitive battery cell production in Germany.

Plasma nitriding is an established process for the surface-hardening of steels and is implemented for a multitude of tools and components. The nitriding result, thereby, depends considerably on the utilized steel materials and the process parameters. Knowledge concerning the process control is largely based on empirical values with frequently used materials. In order to select an ideal plasma nitriding process for new materials and applications, elaborate preliminary tests are generally necessary. At the Fraunhofer IST, a prediction tool has therefore been developed forecasting the results of plasma nitriding processes, thereby, enabling an improvement in the quality of treated components.

The corona pandemic presents major challenges for society, the economy and science. The common goal is to find a way out of the crisis as quickly as possible, the protection of humans must thereby remain the top priority. The scientists at the Fraunhofer Institute for Surface Engineering and Thin Films IST in Braunschweig are also providing an important contribution through their developments, by activating their networks, developing project ideas and supporting industry and society in their endeavors to cope with the direct effects and subsequent outcomes. A number of projects are thereby directly supported by the Fraunhofer-Gesellschaft using internal funds within the framework of the central action program “Fraunhofer vs. Corona”.

Im Graduiertenkolleg »RNApp« entwickeln Universitäten, Kliniken und Fraunhofer-Institute in insgesamt 12 Promotionsvorhaben wegweisende Innovationen in der Grundlagenforschung von RNA-basierten Therapeutika einschließlich smarter Primärpackmittel und erschließen deren Translation in die klinische Praxis. Zu den Herausforderungen therapeutischer RNA-Varianten gehören die Herstellung, Formulierung und Lagerstabilität sowie der Transport zu ihren Wirkorten im Körper.

The EOSS® system concept for coating optical interference filters was transferred to industry on the basis of plant-manufacturer licensing. Suitability of the system for use as a production facility outside the IST was successfully demonstrated.

The SE.MA.KI project is aimed at the planning of an overall concept for a production system for coating technology. The interfaces to other production technologies are essential for the success of the work. The implementation will initially be focused on the automotive interior of the future, as well as mechanical and systems engineering. Following the establishment of the overall system, further applications from differing mobility sectors will be addressed. In collaboration with partner institutes of the Fraunhofer-Gesellschaft and (above and beyond the SE.MA.KI project) the Technische Universität Braunschweig, production-integrated coating solutions will be developed and implemented. The results will be used at the Fraunhofer IST for the planning and construction of a flexible production system.

Multifunctional layer systems form the basis for a new understanding of manufacturing and thereby enable new material composites to be optimally processed in injection molding in the shortest possible time. In the Smart NFR project, sensor modules were integrated into the injection-molding process in order to determine the temperature distribution and flow dynamics of the melt in real time. In addition, it was possible to demonstrate wear optimization compared to natural-fiber-reinforced plastics.

Bending, drawing, rolling, pressing - there are many possibilities for forming sheet metal. All methods, however, have one thing in common: enormous forces and fluctuating temperatures often lead to flaws in the sheets. To prevent this and to increase the efficiency of the process, sensor systems are being developed at the Fraunhofer IST which measure forces and temperatures during the forming process.

Development of a new, future-oriented MEMS assembly group (MEMS: microelectromechanical systems) for use as inertial sensors for the detection of multi-axial accelerations, rotation rates, magnetic fields, etc. in consumer devices such as smartphones, tablets, smartwatches, fitness wristbands or means of transport (Segway, drones).

Loose screws in important connection joints pose a considerable safety risk. The research center IoT-COMMs – part of the Fraunhofer Cluster of Excellence Cognitive Internet Technologies CCIT – has therefore developed an intelligent screw connection which enables wireless and energy-independent monitoring. A thin-film sensor measures both the forces acting on the screw connection and changes in the ambient temperature at the installation site, thereby enabling long-term surveillance.

In collaboration with the IWF of the TU Braunschweig, novel CVD diamond micro-grinding pencils have been developed at the Fraunhofer IST for particularly demanding grinding operations in which particular precision and the highest surface qualities are required. The novel aspect of the tool concept presented is that a polycrystalline CVD diamond layer is used as a grinding layer. In addition, structures are introduced into the tool surface to create further chip spaces.

At atmospheric pressure, plasmas can be generated in very small volumes with dimensions of just a few micrometers, enabling surfaces to be functionalized locally. Within the framework of the BMBF-funded P3T project, a process chain was developed that enables metallic conductor tracks for sensors or RFID to be produced on plastic films from roll-to-roll in a cost-effective and resource-saving manner by means of an additive process.

The AMPFORS project was carried out by the Fraunhofer IST in collaboration with its project partners OHB System AG and Rauch CNC GmbH from 2017 to 2019. The initial situation was that in aerospace, many structural components are made from metal and via subtractive methods (turning, milling) for strength reasons. This makes them unnecessarily heavy. The goal of the project was to use polymers as well as additive processes in order to make the components significantly lighter. Challenges were that there were no limitations on strength as well as electrical conductivity.

The resource-efficient production of plastic components by means of injection molding is dependent on a precise temperature control of the molds. In order to improve the design and monitoring of the temperature control, the real temperatures and pressures must be recorded during the injection-molding process. For this purpose, the Fraunhofer IST has developed a sensory insert for a coupling coated with a media-resistant multi-sensory thin-film system which, in direct contact with the passing water, should enable the measurement of the variables temperature, pressure and flow rate.

Transparent optical lenses with high scratch protection are needed in many sectors today: from the watch industry, through optical instruments and sensor systems, and on to medical technology. The aim of the research project is the development of an ultra-hard optical diamond coating for use in anti-reflective (AR) coatings. The objective is to achieve transparent, scratch-free surfaces and long component lifetimes.