Research Highlights from Dresden

The integration density of active components is a key factor in the development of new products.

Ball screw drives are the drive systems most commonly used in machine tools.

Infrasonics, airborne sound and ultrasound for condition monitoring

Today, a large variety of sensor information is already utilized for condition monitoring in production.

The components of adaptable processes adapt to changing properties of natural and synthetic materials and to changing process conditions, so guaranteeing higher process stability. Due to automated processing they can be used for a wide range of goods and can be integrated into adaptable value creation chains

As part of the project “Development of a Gas Adsorption Heat Pump with a Crystallized Zeolite Heat Exchanger and a New Evaporator- Condenser Apparatus (A DOSO)”, funded by BMWi, the Fraunhofer IFAM in Dresden is working with Stiebel Eltron GmbH & Co. KG, SorTech AG and the Fraunhofer Institute for Solar Energy Systems ISE in Freiburg to develop a highly efficient adsorption heat pump for the provision of hot water and heat in residential buildings.

Microphysiological systems, in which organs and organ systems are “created”, are a promising alternative to animal testing. Therewith, complex mechanisms of the human body can be realistically analyzed. Among other things, these microsystems contain channels, reservoirs, actuating elements, sensor technology and 3D scaffolds “made by laser”. The Fraunhofer IWS offers partners from the fields of biology and medicine complete solutions for microsystem
technology – from design to prototype, including the automation system.

Because of low specific weight, cost-effective production and simple processing, plastic films are used in many industry sectors.

Intelligent IP design flow

Today, ICs are only designed efficiently by means of software. But this automation is hardly possible for analog components on chips. The consequence is disproportional big effort as well as high development costs and risks.

Floating homes are becoming increasingly popular in Germany – not only as holiday homes, but also as permanent residences. In the coming years, this way of life of living on water can help boost the attractiveness and economy of less appealing regions, such as the former coal-mining region Lausitz in Saxony.

As an intermediate public transport vehicle, it combines features of conventional buses (e.g. high flexibility, low infrastructure costs and moderate life cycle costs) with the advantages of trams like high transport capacity, driving comfort and the possibility of partial emission-free operation.

Ceramic nanofiltration membranes for the processing of oil sands

il extraction from oil sands requires a large amount of water for different processes. Hot water used to reduce the viscosity of the oil makes up the largest share. After oil/water separation, the water is sent to the tailings ponds and can be reused as “recycle water“ without any further treatment.

Ceramic phosphors in metal processing

For a reliable, clear and tamper-proof marking of semi-finished and end products there are a variety of labeling solutions on the market. These range from a simple serial number to integrated RFID chips (Radio Frequency IDentification).

Complex hardmetal tools out of the 3D printer

High mechanical and chemical as well as a high temperature resistance and extreme hardness are required for tools that are used in mechanical and automotive engineering or in the construction and forming industry.

Coating engine components with hard carbon reduces friction to almost zero – a development that could save billions of liters of fuel worldwide every year. Now researchers have developed a new laser method to apply the coating on the production line.

Environmentally friendly and cost-effective stationary energy storage systems

Stationary energy storage systems are key element of a modern and sustainable energy supply. Globally growing energy supply and the steady increase of peak loads call for reliable solutions.

New battery concepts for electric vehicles

Driving enjoyment and electric drive – two terms that are no longer contradictory. Today, hardly any automobile manufacturer goes without an “e-car“ in its range of models.

Steadily rising gas prices, an increasing desire for detachment from the turmoil on international raw materials markets and the obligation to save both the local environment and the global climate: these are the main reasons for communities, public transport providers and transport associations to develop new concepts for the operation of electric buses.

The high potential of additive manufacturing is opposed to the large variety of unsolved issues. These issues can only be solved in a close collaboration between science and industry.
Fraunhofer IWS initiated the project "Additive Manufacturing" (Agent3D) to advance the required collaboration.

Intelligente image sensor system-on-chip

Researchers at Fraunhofer IIS/EAS have developed an image processing system that detects positions and movement patterns, and automatically attributes these to people or objects.

Since as early as the 1950s, toxic chemicals such as formaldehyde have been used to inactivate pathogens for so-called killed vaccines (e.g. to fight influenza, polio or hepatitis A viruses)

Researchers of the Fraunhofer IWS have developed a laser-assisted procedure for localized surface layer hardening. Through laser heat treatment of the surface layer with two semisimultaneously working lasers and a subsequent hardening, they succeeded in producing a consistent wear and fatigue-resistant surface layer. The result is a hardness zone, in geometrical terms optimally adapted to the localized wear and stress of turbine blades.

In order to optimize cleaning processes we develop optical monitoring systems and innovative cleaning technologies for all areas of industrial cleaning. Our know-how and extensive testing facilities enable us to experimentally simulate industrial cleaning processes and test and improve the hygienic design of machinery. Our technology developments in the area of adaptive cleaning mean that empirical systems can be replaced by model-based design, parameterization, and control. These are based on inline analysis systems and diagnostic systems, complemented by cognitive control concepts.

In the animal kingdom, the swarm behavior of birds, fish or gregarious animals shows how a multitude of individuals can move effectively and fluently in a very confined space. The intelligent transport systems of the future will take this kind of behavior as a reference point. The Fraunhofer IVI drives these developments in several research projects.

The maximum processor performance is limited by the heat removal efficiency. Therefore, a highly effective cooling technology as well as an innovative power management are the keys to increase the computing power.

With respect to the complexity of requirements regarding reliability of extremely stressed lightweight construction and to the application of latest material developments, the aerospace industry still represents one of the most essential economical and scientific driving forces. Fraunhofer IWS contributes to developing the necessary technologies.

In boxing clinch means a tight clinch of the opponent from which he can hardly break lose. A very tight connection is also the meaning of clinching in terms of joining technology.

Two- and three-dimensional micro and nanostructures facilitate completely new surface features. Two prominent examples of nano- and microstructures with functional properties are the water-repellent lotus effect and the friction-reducing sharkskin.

Self-sufficient waste water treatment by ceramics

A life away from car noise and exhaust fumes – more and more people are attracted to the water. Energy-efficient swimming houses not only fulfill this vitality, but also stimulate the economy of structurally weak regions.

The laypersons calls it 3D printing, the expert talks about additive manufacturing. Strictly speaking, nothing is printed, but built up layer by layer using various materials.

Hardly any fast-growing technical industry can exist without components for microsystems technology in terms of sensors and actuators. In order to meet the growing demands on the performance of micromechanical components and expand the technical base for new applications, further miniaturization is essential

Research in the areas of electromobility as well as stationary energy systems is a central subject at IWS in Dresden. Important contributions can be provided to battery fabrication processes based on the numerous IWS manufacturing process technology development areas.

Innovative »More than Moore« technologies

Traditional chip layouts increasingly reach their limits. For many applications, components have to be laid out even more compactly and with even higher performance than is customary today. For this reason the future belongs to three-dimensionally designed microchips.

In the field of emergency response, complex strategic and operative-tactical decisions have to be made constantly. This applies for large-scale disasters as well as for large events and the daily operation. To support these processes effectively, the Fraunhofer IVI has developed the MobiKat technology in collaboration with experts and responders from fire departments, emergency services and police.

Environmental noise has a decisive influence on health and quality of life.

Being able to find one’s way within the transport network of big cities, to individually choose the means of transport and to be guided to one’s destination reliably and independent from  vehicle changes and interruptions – that is the concept of the public transport navigation system developed by the Fraunhofer IVI

Organic semiconductors enable large area components, for example organic light-emitting diodes (OLEDs) on flexible substrates.

In Germany more than 200,000 people need a hip prosthesis every year

Structured procedures for process analysis allow the identification of interactions and parameters in forming, filling, and sealing processes and also industrial cleaning processes. Systematic data evaluation enables the determination of causal and stochastic relationships between process states, quality parameters, effectiveness parameters, and efficiency parameters.

The hybrid bonding technology is jointly developed by XPERI (Invensas) and IZM-ASSID on 300 mm wafer size.

We develop technologies for packing foods, cosmetics, medical products, and pharmaceuticals and for wrapping technical goods with flexible laminates. We focus on thermal joining using hot contact, laser, and ultrasonic methods and thermoforming using self-developed heating and forming tools. Other key areas of work are the processing of web materials and the design of easy opening packaging systems.

Providing the expanding population with healthy foodstuffs is an enormous challenge whose solution begins very early in the production chain.

Remote laser cutting allows for sublimation cutting without further cutting gas assistance. Thanks to continuously developing the procedure multiple materials can be processed. The technology was introduced in manufacturing halls and application labs, in order to costeffectively
cut non-stampable geometries.

Safe design of persistent and reliable semiconductor components

A large part of automotive innovation is based on high-performance electronics. The components that are available for this today have been developed for consumer goods.

Almost 40 percent of the total energy consumption in Germany is attributed to buildings.

Affordable wireless sensor systems for real time communication

Interconnected, intelligent sensors are the key components for using modern information and communications technologies in industry.

The spatial light modulators developed at Fraunhofer IPMS consist of arrays of micromirrors on semiconductor chips, whereby the number of mirrors varies depending on the application, from a few hundred to several millions.

Ultra-thin glass is thinner than paper. It is that flexible, that it could be wound into rolls.

Smart glasses and wearables are not only a trend but open a wide range of applications in different areas.