formnext 2024

For a sustainable future: efficient repair and modification of products

Our vision is a sustainable society in which products are used for a long time and the right to repair is a matter of course. To achieve this, we have developed an innovative strategy for the repair and modification (remanufacturing) of components. The further development of existing production systems has resulted in a flexible and resource-saving solution that makes it possible to open, dismantle, repair and adapt components.

Our solution

• Further development of an additive-subtractive manufacturing system (hardware and software)
• Laser system for minimally invasive processing
• Digital process planning for iterative, component-specific combination of individual production steps

Benefits

• Resource-saving repair and modification of products such as electric motors
• Increase in the number of variants even after the manufacturing process, as used components can be modified
• Efficient production and customization of components with high diversity
• Contribution to sustainable and long-lasting product use

Optimized foam core structures for lighter and more sustainable vehicles

In the mobility sector, the use of lightweight sandwich structures is becoming increasingly important in order to improve weight and thus emissions and sustainability. Foam cores used between solid outer layers offer many advantages, such as better thermal insulation and sound absorption. However, current foam structures are uniformly designed and have untapped optimization potential for additional weight savings.

Our solution

• Production method for chemical liquid foams in combination with additive application process
• Production of structurally and density graded foam cores
• Analysis and optimization of manufacturing parameters for lighter structures

Benefits

• Flexible, additive manufacturing of anisotropic and optimized foam cores
• Improved process through seamless integration of functionalizations into the core structure
• Lighter and more efficient vehicle components for improved sustainability

Energy-efficient UV curing of glass fiber composites

The mobility industry places high demands on sustainable and economical production methods. We have developed a process for curing fiber-reinforced composites (FRP) using ultraviolet radiation (UV) that significantly reduces both energy consumption and cycle times in production.

Our solution

• Optimized UV curing for FRP with carbon fibres
• Use of photo-initiated polymers for flexible and highly productive manufacturing processes
• Digital and optimized process control for precise and efficient production

Benefits

• Cost savings, as industry-standard thermal post-curing in resin transfer molding (RTM) or wet molding becomes obsolete
• Significantly shorter production times
• Efficient curing, even with hybrid materials

Tailor-made multi-material components for the future of electromobility

Efficient electric machines are the key to the electromobility of tomorrow. Additive manufacturing opens up completely new design possibilities to optimize electric machines in terms of efficiency, size, performance and torque. The combination of different materials in a single manufacturing process makes it possible to overcome conventional limitations and realize innovative motor concepts.

Our solution

• Use of additive and subtractive manufacturing methods to process different active materials simultaneously
• Topology optimization and multi-material construction to overcome existing limitations
• New design freedom in the design and optimization process for electrical machines that meet structural-mechanical, magnetic, electrical and thermal requirements

Benefits

• Optimization of the efficiency, size, performance and torque of electrical machines
• Realization of new machine architectures with tailor-made multi-material components

Qualification of copper for the binder jetting process

In modern electric vehicles, there are a large number of heat-sensitive components that need to be protected from waste heat in order to ensure their functionality. In particular, the charging process with high currents poses challenges for thermal management, which is why more efficient heat exchangers are required. Additive manufacturing using binder jetting enables the efficient production of complex structures made of copper. This allows the effective exchange surface to be increased.

Our solution

• Production and qualification of copper powders specially adapted to the process
• Holistic process optimization of the binder jetting process (BJT)
• Production of a demonstrator heat exchanger using thin-walled structures to increase the exchange surface area

Benefit

• Improved heat transfer through the use of additively manufactured copper structures
• More efficient thermal management can enable faster charging processes and at the same time protect heat-sensitive components in electric vehicles

Increased efficiency for PEM fuel cells through innovative flow structures

The efficiency of fuel cells is crucial for electromobility. We use innovative production techniques to improve the performance of polymer electrolyte membrane (PEM) fuel cells. Our focus is on the development of flow-optimized gas diffusion layers (GDL) and bipolar plates (BPP) as well as the targeted adaptation of surfaces to optimize gas distribution and water management.

Our solution

• Combined additive and subtractive laser process for the targeted creation of flow-adapted channel structures in the GDL and BPP
• Structuring of the surface to influence the water pipe
• Development of a hybrid graphite material for additive manufacturing of the GDL
• Optimization of the gas/water flow through flow simulation
• Metrological analysis with regard to electrical and thermal conductivity, water management and gas distribution

Benefits

• Precise and functional flow structures for optimized fuel cell performance
• Optimized quality of the component: Minimized distortion and at the same time high precision in the production of filigree channels

Efficient cooling of cutting tools through additive manufacturing

The additive manufacturing of cutting tools offers new opportunities to revolutionize the supply of cooling media to the cutting zone. Currently, the cooling flows in identically manufactured channels vary due to differences in quality. With an optimized cooling channel design, tools such as grooving tools can be used optimally in production.

Our solution

• Process optimization of additively manufactured cooling channels in the PBF-LB/M
  • Selection of the ideal particle size distribution
  • Process control variable analysis depending on the particle size distribution
• CFD-based optimization of the cooling channel geometry

Benefits

• Lower pressure losses during through-flow
• Reduced wear
• Increased tool life and productivity of cutting tools

Sustainable production of near-net-shape semi-finished products using binder jetting

Broaching is a key manufacturing process for producing high-quality gears, particularly in the field of electromobility. The cutting edges of the step-shaped broaching tool cut the material under high forces and produce the desired gearing. The production of such broaching tools from high-speed steel (HSS) has so far required energy-intensive soft machining steps. However, it can be made more sustainable and resource-saving.

Our solution

• Production of near-net-shape semi-finished products from high-speed steel (HSS) using binder jetting to eliminate soft machining steps
• Optimization of the process chain for high component density and load capacity of the tool
• Sintering step at ambient pressure to save energy
• Holistic optimization of the process chain

Benefits

• Significantly lower material and energy consumption
• Elimination of the soft machining step
• Improved sustainability and cost efficiency in production

Non-circular-rotary-turning of rotor shafts for electric traction drives

A secure shaft-hub connection between the rotor shaft and laminated core is crucial for long-lasting and efficient electric motors. However, the cylindrical press-fit connections currently in use hinder optimum magnetic design and generate high mechanical stresses that can reduce service life. A pre-stressed positive-locking WNV with a non-circular cross-section of the rotor shaft offers great potential here. Until now, however, there has been no economical production technology for this solution.

Our solution

• Further development of non-round turning for the economical production of new types of rotor shafts with non-round cross-sections
• Studying geometric and process-related degrees of freedom for efficient product-production coupling
• Simulation of the process parameters to optimize the cross-sectional mapping and customizability of the component
• Validation of the simulation results through experiments and preparation of practical recommendations for industrial application

Miniature version of the test vehicle

The miniature vehicle “Mini-eVee” is the third model in the ICM vehicle fleet and is used for demonstration and validation purposes. It reproduces larger vehicle concepts on a scale of 1:4 and thus enables early concept studies and installation space investigations.

Thanks to its compact dimensions and the intensive use of 3D printed parts, new ideas can be visualized and tested at an early stage of development. MinieVee provides a flexible platform to test innovative technologies before they are transferred to larger models.

Technologies tested in Mini-eVee

• Design study with carbon fiber reinforced plastic (CFRP) through towpreg technology
• All-wheel drive (4WD) with four motors close to the wheels and torque vectoring
• Individual all-wheel steering for smaller turning circles and improved agility
• Integrated push-rod mechanism for optimized space and stability
• Future E/E architecture with web-based interface and Car-to-X communication

Lightweight construction is a very important component for the sustainable mobility of the future. This approach enables a decrease in the energy demands of vehicles. However, conventional lightweight materials such as glass fiber and carbon fiber reinforced polymers (GFRP and CFRP) as well as aluminum emit significant amounts of CO₂ during their production. In addition, their recycling is technically possible but economically challenging.

To enable sustainable lightweight construction, natural fiber-reinforced composites (NFC) are currently in focus in fiber composite research.
The production of NFRP still presents some challenges in terms of the quality of the composite. The Institute of Aircraft Design at the University of Stuttgart has developed a new manufacturing technology to produce NFRP with high quality. A new NFRP production technology is being further developed as part of the ICM-project “NaturStoff”.

<meta charset="UTF-8" />Wasserstoffdrucktanks werden in Fahrzeugen extremen Speicherdrücken von bis zu 700 bar ausgesetzt, erfüllen jedoch keine zusätzliche lasttragende Funktion. Wir entwickeln bauraumangepasste Wasserstoff-Druckspeicher, die möglichst viel Wasserstoff speichern und zugleich als Versteifungselemente in der Fahrzeugstruktur dienen. Dazu werden Metal Organic Frameworks (MOFs) in den Tanks eingesetzt. Diese mikroporösen Materialien binden den Wasserstoff wie ein Schwamm und senken den Betriebsdruck im Behälter.

Unsere Lösung

• Lasttragende Strukturintegration der Wasserstoffspeicher in die Fahrzeugstruktur
• Nutzung von Metal Organic Frameworks (MOFs) zur Stabilisierung und Drucksenkung
• Bauraumangepasste Tankgeometrien durch formadaptive Linerstrukturen (Liner = Kunststoff-Innenhüllen der Tanks)
• Herstellung der Liner mittels additiver Fertigungstechnologien

Nutzen

• Erhöhtes Leichtbaupotenzial durch die Nutzung von Versteifungselementen
• Optimale Platzausnutzung im Fahrzeug dank flexibler Tankformen
• Effiziente Wasserstoffspeicherung bei reduziertem Betriebsdruck
• Branchenübergreifende Anwendbarkeit, nicht nur im Automobiksektor