Fraunhofer Institute for Microstructure of Materials and Systems IMWS
Fraunhofer Institute for Microstructure of Materials and Systems IMWS
© Diehl Aviation Laupheim GmbH
Thermoplastische Sandwichstrukturen sollen die effiziente Herstellung von Gepäckfächern in der Flugzeugkabine ermöglichen, hier eine Handgepäckablage.

Sustainable lightweight solutions for aircraft cabins thanks to efficient thermoplastic technology

Lightweight construction is crucial for aviation. In the "STair" project, Diehl Aviation, Ensinger, ThermHex, and the Fraunhofer IMWS are developing new thermoplastic lightweight components for aircraft cabins that can be processed more quickly and are significantly more environmentally friendly.

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© Diehl Aviation Laupheim GmbH

© Fraunhofer IMWS
Im Projekt hergestellte Wabenkern-Sandwichstrukturen aus recyceltem Polypropylen-PET mit Glasfasern (rPET/GF) hergestellt.

Lightweight design with sustainability in mind – Recycled plastics in sandwich components

In the current project “rSandwich,” the Fraunhofer IMWS is working on manufacturing sandwich components based on recycled materials under industry-relevant conditions. To support this, material-specific analysis methods and material adapted simulation models are being developed, enabling precise predictions of material properties and, in particular, the effects of recycling.

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© Fraunhofer IMWS

© Fraunhofer IMWS
Thermoplastic UD tapes offer great potential for lightweight construction in structural applications.

Improved simulation methods for sustainable plastics

Digital solutions for process and material simulation for compounds based on thermoplastic recyclates, 3D-printed plastic components, and UD tapes will be developed in the "MikroSimPlast" project.

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© Fraunhofer IMWS

Innovative sorting technologies in recycling

On October 2, 2025, the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE will host an online seminar presenting innovative sorting technologies that are seen as key to addressing the major challenges in plastic recycling.

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© Fraunhofer IMWS
Recyclates made from bio-based PBS. These can be processed by compounding.

Solutions for sorting and recycling polybutylene succinate (PBS)

lastics based on polybutylene succinate (PBS) offer great potential for sustainable packaging. The Fraunhofer Institute for Microstructure of Materials and Systems IMWS has now presented solutions for this.

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© Fraunhofer IMWS

Skalierung PA-Recycling
© Fraunhofer IVV
Bis in den Pilotmaßstab (hier das Großtechnikum am Fraunhofer IVV) haben die Projektpartner ihre Lösungen skaliert.

Efficient recycling and expanded use of plastic waste streams

Eight Fraunhofer Institutes have developed new solutions for waste management and the circular economy of plastics in the lighthouse project "Waste4Future". With their expertise, they are improving aspects such as recycling, sorting, recipe development, utilization paths and the minimization of waste streams.

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© Fraunhofer IVV

Fünf Preisträger aus dem Projektteam mit dem Award..
© WortBildWert / Juliane Ziegler
Prof. Dr. Maik Feldmann und Dr.-Ing. Ralf Schlimper vom Fraunhofer IMWS freuen sich mit den Projektpartnern Jochen Pflug (ThermHex), Friedrich Zierling (ThermHex) und Matthias Biegerl (Elring Klinger, von links) über die Auszeichnung.

Efficient production of sandwich components: Fraunhofer IMWS honored with JEC Innovation Award

In the "HyWaSand" project, Fraunhofer IMWS was honored in Paris with the JEC Composites Innovation Award 2025 for its innovative lightweight storage flap and manufacturing process.

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© WortBildWert / Juliane Ziegler

Innenmischer Kautschuk
© Fraunhofer IMWS
Inline erfasste Daten aus dem Mischsaal helfen dabei, die Rezepturen und Herstellungsverfahren für Kautschuk-Compounds zu optimieren.

Accelerated development and manufacturing processes for rubber compounds

The Fraunhofer IMWS in Halle (Saale) is working with six partners to develop intelligent algorithms and methods that support the production of application-optimized rubber compounds. The goal is software that uses information on formulation and processing conditions to derive predictions and optimization strategies.

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© Fraunhofer IMWS

© Fraunhofer IMWS
Basalt-Schnittfasern mit optimaler Schlichtung (links) wurden als Ausgangsmaterial für ein Basaltfaser-Polypropylen-Granulat (rechts) genutzt, das im Spritzguss verarbeitet werden kann.

Basalt fiber-reinforced polymer compounds for lightweight construction applications

Compared to glass fibers, basalt fibers offer considerable advantages in terms of energy consumption and environmental friendliness when used as a reinforcing component in thermoplastics. An automotive strip produced by injection molding as a project result demonstrates the potential of this material combination.

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© Fraunhofer IMWS

Cost-effective and sustainable solutions for plastics technology

We have many years of experience in the field of thermoplastic and rubber materials and a deep understanding of the relationships between process, structure, and properties. We combine this expertise with state-of-the-art, industry-relevant technology and application-oriented material diagnostics. This unique combination enables the rapid and low-risk development of new material formulations, semi-finished products, and components up to the pilot scale.

We specialize in fiber-reinforced high-performance thermoplastics and innovative rubber composites for high-volume production. Our focus is on plastics processing and the optimization of polymer materials to improve energy and resource efficiency. We serve customers in the mobility sector (automotive, aerospace, and rail) as well as in the plastics industry and mechanical engineering. Our offerings include solutions for lightweight construction, tire applications, and bio-based plastics. We cover the entire value chain, from microstructure to custom-made components, and provide research services across the entire development chain. With the PAZ pilot plant center for polymer synthesis and processing in Schkopau, we have excellent capabilities for scaling up polymer innovations.

What sets us apart:

  • Excellent expertise in materials and processes related to fiber-reinforced high-performance thermoplastics and innovative rubber composites
  • Comprehensive analysis of the entire value chain, from the microstructure of the material to the custom-made component
  • Excellent facilities with a wide range of methods
  • Equipment up to industrial scale enables effective support for scaling and prototype testing
  • Expertise in virtual process chains for material design, process technologies, and component properties

What you can expect:

  • Consulting on the selection of raw materials
  • Development of customized material behavior through microstructure design
  • ·Comprehensive understanding of processing technologies (microstructure – manufacturing process – component properties), including the development of new manufacturing processes
  • Characterization of material properties at the laboratory, pilot plant, and industrial scale
  • Analysis of component properties, including prediction of in-service behavior
  • Modeling and simulation

 

Research Topics

 

Sustainable rubber compounds

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Sustainable thermoplastic compounds

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Application-specific UD tapes

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Tape-based thermoplastic lightweight structures

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Composite sandwich structures

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Assessment of plastics, processes and components

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Range of Service:

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Polyamid Granulat Kunststoff Spritzguss
© Fraunhofer IMWS
Nylon granules are formed into plastic parts by the injection molding process.

The Fraunhofer IMWS offers a wide range of options for the development of new polymer materials with specific properties. The starting point is the microstructure of materials: understanding and mastering this level, together with the relationships between molecular structure, morphology, and the mechanical properties of polymer materials, opens up the possibility of targeted optimization of materials for specific applications.

The institute’s expertise encompasses both the development of new material concepts and the optimization of existing polymer materials with regard to their physical and mechanical properties for innovative applications.

The institute’s team always considers the integration of efficient processing technologies as well as the necessary quality control. The focus is on material development for the use of bio-based and recyclable plastics, as well as on the further development of thermoplastically processable, super-elastic polymers, nanostructured copolymers, and elastomer and thermoplastic systems modified with nanoscale fillers.

Fraunhofer IMWS supports with:

 

  • Development of material concepts to optimize the mechanical properties of copolymers and nanocomposites
  • Compounding and processing of copolymers with additives and fillers from lab to pilot scale
  • Melt rheology and dynamic-mechanical analysis
  • Structural investigations on copolymers and nanocomposites (nanoscale morphology, crystalline structure, filler dispersion and distribution)
  • Mechanical materials characterization (dynamic–mechanical–thermal and quasi-static loading, fracture mechanics, crack kinetics, strain-field analysis) and correlation with morphology to actively influence material properties

The Fraunhofer IMWS is distinguished by excellent facilities and extensive expertise in process engineering and plastics processing. The portfolio includes a range of processing technologies and, in particular, emphasizes the interplay between material, process, and material performance, as well as solutions for scaling up to industrial-scale production.

The institute supports its clients with:

For 3D printing at the institute, the materials used and the quality-control methods are optimized.
  • Injection molding: development and optimization of injection molding processes for various plastics
  • Extrusion: research and improvement of extrusion processes for producing plastic profiles and films
  • Additive manufacturing: application of 3D printing technologies for processing plastics
  • Composite materials: development of methods for producing fiber-reinforced plastics
  • Process simulation: use of simulation software to predict and optimize processing processes
  • Quality control: implementation of methods to monitor and ensure product quality during processing

In the field of polymer-based component development, we can provide a wide range of customized solutions for our clients. Our particular expertise lies in integrating component development with upstream and downstream processes, such as material development, adaptation of processing technologies, and analysis of component properties—including the prediction of performance in actual use. Our capabilities range from single-unit prototypes to pilot-scale production.

© Fraunhofer IMWS
As a demonstrator, the institute manufactured a storage-compartment lid from thermoplastic sandwich structures.

 

Our expertise includes:

  • Production of pilot and small series
  • Component manufacturing under industrial conditions
  • Automated component removal
  • Manufacturing documentation
  • Technical capabilities for rapid tool prototyping
  • Pilot-scale production capabilities
  • Comprehensive evaluation of components and materials
  • Sampling and production of pilot series (initial sampling, follow-up sampling)

As a research institute with a strong methodological foundation and a core expertise in the microstructural analysis of materials, Fraunhofer IMWS offers first-rate capabilities for the characterization, structural analysis, and evaluation of plastics. The institute’s clients benefit from a wide range of characterization methods, many years of expertise, and state-of-the-art equipment.

© Fraunhofer IMWS
Tensile test on a laminate tape.

These include:

  •  High-resolution microscopy: Use of electron microscopy (SEM, TEM) to analyze the micro- and nanostructure of plastics
  •  X-ray analysis: Non-destructive testing using X-ray CT; application of X-ray diffraction (XRD) to determine crystalline structure and perform phase analysis
  • Thermal analysis: Performing DSC (differential scanning calorimetry) and TGA (thermogravimetric analysis) to investigate the thermal properties of polymers
  • Mechanical testing: Investigation of mechanical properties such as tensile strength, hardness, and impact strength
  • Chemical analyses: Use of techniques such as FTIR (Fourier-transform infrared spectroscopy) and GC-MS (gas chromatography-mass spectrometry) to identify chemical compositions
  • Aging and service life analyses: Investigation of the long-term stability and aging processes of plastics under various conditions

© Fraunhofer IMWS
Fiber orientation analysis of laminates made from UD tapes is performed using different orientation angles (0°/+45°/90°-45°).

Digital and numerical methods play a key role in the Fraunhofer IMWS’s range of services for polymer processing and characterization. They enable the minimization of material and production costs by optimizing processes even before physical implementation, the shortening of development times through early identification of problems and design adjustments, and the improvement of processing efficiency and quality through precise simulation of process parameters. In addition, effective simulation solutions help minimize risks such as errors and failures because they allow the behavior of materials and components under various conditions to be predicted. Last but not least, they enable significant leaps in development, for example through comprehensive analyses and testing of materials and products in a virtual environment.

Fraunhofer IMWS's areas of expertise include:

  • Process simulation: Modeling and simulation of manufacturing processes such as injection molding and extrusion to optimize process parameters
  • Structural analysis: Use of finite element methods (FEM) to analyze the mechanical properties and behavior of plastic components
  • Flow simulation: Computational Fluid Dynamics (CFD) to investigate flow behavior and heat transfer during processing
  • Thermal simulation: Analysis of heat distribution and dissipation in plastic components during processing and use
  • Service life predictions: Simulation of aging and fatigue processes to predict the service life of plastic products
 

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