Fraunhofer Institute for Microstructure of Materials and Systems IMWSSandwich structures combine rigid outer layers with a lightweight core, resulting in high bending and buckling stiffness with low weight. A process developed at the Fraunhofer Institute for Microstructure of Materials and Systems IMWS enables the efficient, automated production of 3D-shaped and functionalized sandwich components at a rate of several per minute, for example for the automotive industry. The institute will present the technology, which won the JEC Award 2025, at the K trade fair from October 8 to 15, 2025.
As a demonstrator, visitors to stand 70SC05 in hall 7.0 will be able to see a storage compartment flap for a truck cabin that has been manufactured using thermoplastic sandwich molding technology. Semi-finished products with a thermoplastic honeycomb core and cover layers made of fiber-reinforced thermoplastic UD tape laminates are processed by thermoforming. Functionalization by injection molding is possible in the same process. The manufacturing process is fully automated, making the process suitable for both molded components and the processing of thermoplastics in large-scale production. The technology, developed jointly with project partners Daimler Truck AG, ElringKlinger AG, ENGEL Austria GmbH, ThermHex Waben GmbH, and Edevis GmbH, was honored with the JEC Composites Innovation Award in the "Automotive & Road Transportation – Process" category in January 2025.
"The sandwich construction enables weight savings of up to 70 percent compared to monolithic structures and at the same time offers a load-bearing capacity that is equal to or even exceeds that of metal components. This is very attractive for heavy-duty structural components, such as those used in automotive and aerospace applications," says Prof. Dr. Maik Feldmann, head of the "Polymer Applications" business unit at Fraunhofer IMWS. "With thermoplastic sandwich molding technology, we are significantly expanding the fields of application for the efficient use of this lightweight construction method. The lower material requirements and the possibility of using recyclable materials are further significant advantages. I am very much looking forward to discussing this with visitors at the K trade fair."
The Fraunhofer team from Halle (Saale) will also be focusing on sustainable plastics solutions in other areas. For example, a child seat made from biopolymer and fiber-reinforced plastics, which also uses recycled materials, will be on display as a demonstrator. New approaches to reducing microplastic emissions will be presented with a tire wear sensor for use in trucks. In addition, Fraunhofer IMWS will showcase its expertise in tape-based lightweight construction and material evaluation.
(September 18, 2025)
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