Highlights 2025 - Fraunhofer IMWS

Research projects, statistics, publications and collaborations 2025

Inhaltsverzeichnis

Foreword by the acting institute director Dr. Christian Schmelzer

Dear Readers,

2025 was not a year of routine for Fraunhofer IMWS. The framework conditions for applied research have continued to intensify: public research funding is under increasing pressure, markets are changing more rapidly, and our partners in industry are also operating in a demanding environment. For Fraunhofer IMWS, 2025 was therefore a year of consolidation, focus, and forward-looking decisions. We did not merely respond to challenges or continue existing activities; rather, we refined our priorities and set the course for necessary changes. The ability to remain fit for the future requires the willingness to critically examine one’s own organization and to develop it decisively further.

Selected research highlights

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Elektronics

Projektübersicht

Characterization, testing, and reliability for heterointegration and chiplets

Project

APECS

Description

As part of the European APECS pilot line, Fraunhofer IMWS supports chiplet heterointegration with a focus on characterization, testing methods, and reliability. It develops standardized test procedures, metrics, and assessment models, and validates the robustness of complex components and systems under real-world operating conditions.

Impact

• Standardized characterization and test methods establish a reliable foundation for chiplet systems
• Enhanced reliability and scalability of CTR systems
• Provision of validated testing and evaluation tools for European industry

Partner

Fraunhofer ENAS, Fraunhofer EMFT, Fraunhofer AISEC in the Research Factory Microelectronics Germany (FMD)

Link

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Data-Driven materials development for copper applications

Project

"KupferDigital"

Description

Fraunhofer IMWS, together with partners, has developed a central data platform for copper materials. "KupferDigital" enables the collection, networking, and analysis of relevant data.

Impact

• Accelerated copper materials research through a centralized data platform
• Improved reproducibility and knowledge exchange between research and industry
• Shorter development times and reduced costs through data-driven decision-making

Partner

Research Institute for Precious Metals and Metal Chemistry (FEM), Fraunhofer Institute for Mechanics of Materials (IWM), Institute for Applied Computer Science (InfAI), Helmholtz Institute Freiberg for Resource Technology (HIF) at the Helmholtz-Zentrum Dresden-Rossendorf (HZDR), Federal Institute for Materials Research and Testing (BAM), German Copper Institute (DKI)

Link

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Robust inverters for solar and wind power

Project

"power4re"

Description

The "power4re" project has created enhanced capabilities for the material selection and design of inverters for photovoltaic and wind energy systems. It identifies suitable materials (semiconductors, conductive traces, cooling components) and develops integrated design workflows.

Impact

•Increased efficiency and reliability through targeted material selection
• Optimized design processes reduce development time and costs
• Realistic lifecycle estimates and improved predictions of operational characteristics

Partner

Fraunhofer Institute for Wind Energy Systems IWES, Fraunhofer Institute for Integrated Systems and Device Technology IISB, Fraunhofer Institute for Solar Energy Systems ISE, Fraunhofer Institute for Reliability and Microintegration IZM, Advisory Board comprising industrial companies

Link

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AI-Powered failure analysis: defect screening and diagnostics

Project

"FA2IR"

Description

The objective is the application of AI-based methods in failure analysis, defect screening, and diagnostics within microelectronics. Data-driven, automated workflows are being developed to enable early defect detection, root cause attribution, and accelerated diagnostics.

Impact

• Faster failure detection and diagnostics
• Reduction of rejects and quality defects
• Scalable, data-driven quality controls for microelectronics

Partner

Infineon, Bosch, Zeiss, PVA TePla AS GmbH, Matworks GmbH, University of Stuttgart, and other partners from Sweden, the Netherlands, and France.

Link

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Photovoltaics

Projects

Online Tool for rooftop PV systems in Saxony-Anhalt

Project

PV planning tool

Description

An online tool supports the planning of rooftop PV systems in Saxony-Anhalt. It integrates roof data (orientation, pitch, shading), economic feasibility analyses, and funding information to empower property owners, installers, and municipalities in the planning, assessment, and implementation processes.

Impact

• Facilitates the planning and implementation of rooftop PV projects through data-driven decision support
• Enhances transparency regarding costs, subsidies, and site potential for investors
• Supports the regional energy transition and grid planning through real-world data

Partner

State Energy Agency of Saxony-Anhalt

Link

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Solutions for hotspot prevention under partial shading

Project

"SegmentPV"

Description

The project analyzed the effects of partial shading on PV systems, identified the resulting hotspots, and quantified yield losses. Based on these findings, measurement and modeling tools were developed, and practical countermeasures (layout optimization, MLPE, operational management) were derived.

Impact

• More accurate assessment of losses due to partial shading and improved yield forecasts
• Better planning and design decisions through robust models and tools
• Increased system performance and reliability through concrete countermeasures

Partner

AESOLAR

Link

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Classification of cell and microcracks in PV modules

Project

"PV-Riss"

Description

Fraunhofer CSP is developing AI-based imaging methods for the detection, classification, and localization of cell and microcracks in PV modules.

Impact

• Early detection of cracks reduces downtime and maintenance costs
• Improved quality controls reduce scrap
• Data-driven maintenance leads to longer service life

Partner

Forschungszentrum Jülich GmbH, Anhalt University of Applied Sciences, Hanwha Q Cells GmbH, Ingenieur-Büro Kirch, Arp & Kleiss GmbH, Sunset Energietechnik GmbH, German Commission for Electrical, Electronic & Information Technologies in DIN and VDE (DKE)

Link

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Simulation for assessing the reliability of PV systems

Project

"KliMaTe"

Description

The reliability, service life, and failure risks of photovoltaic systems can be assessed and improved using simulation-based models. Fraunhofer CSP is developing solutions that integrate component and system models, conducts sensitivity analyses, and provides forecasts for maintenance, costs, and risk management.

Impact

• Realistic reliability and lifespan forecasts enable optimized maintenance and investments
• Reduced downtime and operating costs
• Improved planning of maintenance strategies and asset management

Partner

Link

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Optical Materials

Project Overview

Reliable petawatt mirror systems for laser fusion

Projekt

"SHARP"

Description

The “SHARP” project is developing petawatt laser mirrors, coatings, and beam delivery systems for fusion experiments. Fraunhofer IMWS is contributing its expertise in materials characterization and process optimization.

Impact

• Increased damage resistance, thermomechanical stability, and excellent beam quality under repeated high-power loads
• Advances in coatings and thermal management extend service life and improve availability

Partner

SCHOTT AG, optiX fab GmbH, asphericon GmbH, 3D-Micromac AG, LAYERTEC GmbH, robeko GmbH & Co. KG, Cutting Edge Coatings GmbH, Laser Zentrum Hannover e.V., Fraunhofer IOF

Link

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Automated and adaptive TEM sample preparation in microelectronics

Projekt

"Adaptive Milling"

Description

The project aims to develop an automated, adaptive workflow for fast and precise TEM sample preparation in microelectronics, with the goal of reducing manual steps and significantly increasing throughput and reproducibility.

Impact

• Significantly higher throughput thanks to automated TEM sample preparation for rapid material analysis
• Improved reproducibility and precision
• Reduced manual effort lowers costs and standardizes the analysis workflow

Partner

point electronic GmbH

Link

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Plastics

Projektübersicht

Solution for lightweight sandwich construction in injection molding wins JEC Award

Project

"HyWaSand"

Description

Using a truck storage compartment door, Fraunhofer IMWS is demonstrating new solutions for injection-molded lightweight sandwich structures featuring ultra-light cores and robust outer layers. The manufacturing process behind this innovation, developed at Fraunhofer IMWS, has been honored with the JEC Award.

Impact

• Scalable, industrial lightweight construction solution for the automotive, aerospace, and mechanical engineering industries
• Advanced joining and manufacturing processes to optimize stiffness, damping, and component weight

Partner

Daimler Truck AG, ElringKlinger AG, ENGEL Austria GmbH, ThermHex Waben GmbH, Edevis GmbH

Link

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Improved sorting, recycling, and formulations for plastic waste

Project

"Waste4Future"

Description

A Fraunhofer team takes a comprehensive approach to plastic waste: effective sorting, efficient recycling, and the development of new formulations and processing methods.

Impact

• Higher recycling rates and improved material quality through integrated sorting and processing
• Development of practical formulations reduces costs and increases recovery
• Integrated material flows, sensor technology, sorting logic, and process control throughout the plastic industry’s circular economy

Partner

Fraunhofer Institute for High-Frequency Physics and Radar Technology FHR, Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Fraunhofer Institute for Optronics, System Technologies, and Image Analysis IOSB, Fraunhofer Institute for Process Engineering and Packaging IVV, Fraunhofer Institute for Material Cycles and Resource Strategy IWKS, Fraunhofer Institute for Non-Destructive Testing IZFP, Fraunhofer Institute for Structural Durability and System Reliability LBF

Link

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Simulation of the microstructure of polymer composites

Project

"MikroSimPlast"

Description

Computer-aided models are used to simulate the microstructure of polymer composites (blends, additives) and predict their impact on strength, thermal conductivity, and processability.

Impact

• Improved prediction of properties based on microstructure
• Accelerated, data-driven material development through simulation-based optimization
• Improved process control through targeted mixing and processing strategies in production

Partner

Link

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Sorting and recycling solutions for polybutylene succinate (PBS)

Project

"RUBIO"

Description

Fraunhofer IMWS develops sorting and recycling solutions for polybutylene succinate (PBS). These include separation and processing methods, recycling pathways, and new processing methods.

Impact

• Improved sorting of packaging waste and its return to the recycling loop
• Reduced environmental impact through closed-loop packaging waste recycling
• Cost-effective packaging waste recycling through standardized processes

Partner

Leibniz Institute for Agricultural Engineering and Bioeconomy, LXP Group GmbH, Fraunhofer Institute for Applied Polymer Research IAP, IMO Service GmbH, Exipnos GmbH, BYK-Chemie GmbH, Saxon Textile Research Institute, POLIFILM EXTRUSION GmbH, Naue GmbH & Co. KG, Optipack GmbH, Technifex Sachsen GmbH, Leipzig Plastics Center, LLA Instruments GmbH & Co. KG, Global Solutions GmbH, Veolia Umweltservice Ost GmbH

Link

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Health Care

Projektübersicht

Surface texturing of dental prostheses and dental splints

Project

"OptiHaft"

Description

Fraunhofer IMWS develops advanced surface structures for dental prostheses and dental splints to improve comfort, biocompatibility, and hygiene. The focus is on microstructured surfaces, antimicrobial coatings, and optimized manufacturing processes; validation is performed using biofilm and biocompatibility tests to assess long-term stability.

Impact

• Improved fit, hygiene, and durability thanks to optimized surfaces
• Reduced biofilm formation thanks to antimicrobial coatings
• Scalable, industrial manufacturing solutions

Partner

ERDF-funded pre-competitive research project

Link

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Perfusion system for human skin

Project

"WoundSensing"

Description

This project aims to maintain the viability of excised human skin through perfusion, thereby making it suitable for research into skin conditions and for the development of skin-related products and diagnostic devices.

Impact

• Animal-free standardization of spectral optical diagnostics for skin conditions
• Provision of reproducible skin and wound conditions
• Improved transferability, safety, and efficacy of skin-related products

Partner

Compolytics GmbH, ILBQ Fritz Höppler e.V. (an affiliate of Anhalt University of Applied Sciences), BG-Klinikum Bergmannstrost

Link

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Biofilm Assessment of Oral Care Products

Project

"BioFilmDental"

Description

Oral biofilm formation and control play a central role in the efficacy of dental care products. Fraunhofer IMWS develops standardized monospecies and multispecies biofilm models, measurement methods, and performance metrics for analyzing the efficacy of antibacterial formulations and materials.

Impact

• Standardized and normalized biofilm models facilitate regulatory compliance and product comparison
• Improved efficacy of antimicrobial formulations; reduced biofilm risk
• Opening up new areas of application in the testing of prophylactic and therapeutic products
• Data-driven optimization supports the market launch of new products

Partner

ERDF-funded pre-competitive research project

Link

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