Reference projects of the Fraunhofer IST

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.