Fraunhofer Institute for Microstructure of Materials and Systems IMWSA new simulation tool for plastics processors is designed to enable the development of functionalized, recyclable components more quickly, cost-effectively, and with greater resource efficiency. The Fraunhofer Institute for Microstructure of Materials IMWS in Halle (Saale) and the Fraunhofer Institute for Industrial Mathematics ITWM in Kaiserslautern are combining their expertise in the field of patented micro-/nanostructuring and multiscale simulation software.
The surfaces of plastic components often require specific characteristics for applications in the automotive sector, medical technology, or the packaging industry – for example, to enable defined adhesive forces, controlled wettability, or optical properties such as diffuse reflection. Currently, these functions are mostly achieved through additives or coatings. This is detrimental to recyclability, as the plastics are then no longer homogeneous. Additionally, process costs increase. A powerful alternative is purely morphological surface functionalization, as developed at the Fraunhofer IMWS: micro- and nanostructures directly generate the desired surface properties.
“With this patented process, which is also suitable for injection molding, we can structure plastic surfaces over large areas using a bionically inspired approach – without any chemical additives,” says Annika Thormann, project manager at Fraunhofer IMWS. “With the new simulation tool, we are making this technology more quickly accessible to the plastics processing industry and laying the foundation for recyclable, resource-efficient products.”
MESHFREE maps the injection molding process from the nano- to the macro-scale
In the “3-ScaleSim” project, the two Fraunhofer Institutes are developing a multiscale simulation tool based on the MESHFREE software, which was developed by Fraunhofer ITWM and awarded the Joseph von Fraunhofer Prize in 2024. The digital twin of the injection molding process links structural design at the macro-, micro-, and nanoscale with material data and process parameters such as pressure and temperature. A nano-micro-macro database, along with accompanying experiments at Fraunhofer IMWS, enables the iterative validation and refinement of the models.
The goal is to largely replace time-consuming feasibility studies with virtual experiments and to reliably evaluate micro-/nanostructuring as early as the initial development phases. “By extending MESHFREE from the macro scale to the micro and nano scales, we are making the entire injection molding process fully simulatable for the first time,” explains Isabel Michel, project manager at Fraunhofer ITWM. “This provides customers with precise predictions regarding structural features and surface properties – while significantly reducing development times.”
Shorter development times for SMEs and applications ranging from automotive to medical technology
The project’s outcome will be a comprehensive process demonstrator comprising micro-/nanostructured injection-molded parts and the associated simulation tool. Plastics processors, particularly small and medium-sized enterprises, can use it to digitally test variations in mold designs, polymers, and process windows before investing in production. This reduces costs and risks, shortens development cycles, and accelerates decision-making.
The technology addresses key challenges in the plastics industry: resource conservation, recyclability, and high functional requirements for plastic surfaces. The plastics processing industry can benefit significantly from this in sectors such as consumer goods, medical technology, packaging, and automotive. In the future, the database-supported approach can also be applied to other materials, such as metals.
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(March 24, 2026)