Projects

Current running projects:

AIF Cornet "SIQ4TFP"

Self Improving Quality for Tailored Fiber Placement Composite Production

Funding period: 12/2021 - 11/2023

SIQ4TFP develops a system that automatically detects the actual fiber depositing path in Tailored Fiber Placement (TFP) and compares it with the target path. Based on the detected deviations and relevant process parameters, the project enables parameterized, automated correction of CNC/NC control data during production. This supports improved preform quality and reduced effort for training new TFP samples, while also enabling passive quality assurance through documented lay-up processes. The results will be used to derive initial material models/inputs for FEA and to optimize TFP production for lightweight applications.

IPF-relevant research objectives

Development of 2D/3D measurement and analysis for layer-by-layer recognition of the actual fiber lay-up path (including fiber course, stitch pattern and surface topography).
Building and using a knowledge base/material database linking deviations and process parameters to resulting composite properties for subsequent FEA/modeling.
Supporting integration and validation of target/actual comparison and transfer of results via TFP-CAM interface (EDOpath) to drive automated corrections and quality assurance.

Project partners

FKT – Forschungskuratorium Textil e.V. — Germany
FIBRE – Faserinstitut Bremen e. V. — Germany
Leibniz IPF – Leibniz-Institut für Polymerforschung Dresden e. V. — Germany
EMBRAPII – Empresa Brasileira de Pesquisa e Inovação Industrial — Brazil
ISIPOL – Instituto SENAI de Inovação em Engenharia de Polímeros — Brazil

Project sponsor

cornet - Collective Research NETworking

DAAD "ENUHVA"

Experimental and numerical characterization methods for variable-axial reinforced elastomers in engineering, biomedical, and industrial applications (ENUHVA)

Funding period: 01.01.2023 – 31.12.2024

ENUHVA develops methods for the experimental and numerical characterization of fiber-reinforced elastomers (FRE), including variable-axial/TFP-based material architectures. Since FRE cannot be modeled in the same way as conventional composites—and cannot be handled reliably with standard hyperelasticity approaches—an end-to-end characterization and modelling protocol is established. The project combines (i) selection and calibration of suitable hyperelastic constitutive models, (ii) an appropriate experimental test strategy, and (iii) software tools supporting model/material identification. A full-scale demonstrator is manufactured and validated through numerical–experimental comparisons, resulting in a transferable protocol for industry and research.

IPF-relevant research objectives

Development/enhancement of modelling and calibration approaches for FRE in the context of variable-axial/TFP-based structures (numerical + experimental).
Provision/extension of software tools to support the selection of suitable hyperelastic models and to perform parameter identification (including integration into FEMU/FEMU workflows).
Validation via demonstrator manufacturing and numerical–experimental verification, leading to an application-ready characterization protocol.

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF) — Germany
Federal University of Rio Grande do Sul (UFRGS) — Brazil

Project sponsor

DAAD PPP/PROBRAL

DFG Transfer "Tiefbohren"

VIBRATION-DAMPING COMPOSITE DRILL TUBES with integrated sensors for deep hole drilling processes

DFG

The BTA deep drilling process enables drilling with high length-to-diameter ratios. However, long tools lead to strong vibrations, especially when drilling high-alloy materials. This increases tool wear and, due to reduced drill quality, results in higher scrap rates for typically very expensive components. The DFG research project developed a vibration-damping composite drill tube with a hybrid connection concept for joining fiber-reinforced plastic (FRP) and metal via a plastic intermediate layer and the integration of fiber optic sensors for process and tool contion monitoring. Part of the hybrid connection concept is an innovative fiber winding pattern that creates form-fit connections with specific thickness changes and thus creates a high-strength connection.

Project partners:

Institut für Spanende Fertigung (Technische Universität Dortmund)
Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP
BGTB GmbH – Beratende Gesellschaft für Tiefbohr- und Zerspanungstechnik
KAISER Maschinenbau und Zerspanungstechnik GmbH & Co. KG
carbovation gmbh

BMWK LuFo VI-2 "LaST"

LaSt – VaLu: Variable-Axial Fiber Architectures of Doubly Curved Fiber-Reinforced Polymer Composites for Aviation Applications (VaLu)

Funding period: 07/2022 - 06/2025

In the LaSt consortium project, Tailored Fiber Placement (TFP) technology is combined with Filament Winding (FW) technology to manufacture load-adapted, isotensoid fiber composite structures on curved surfaces. Key goals include reducing the minimum drapable TFP radius (from R2500 to R100) and producing an aerodynamically conforming Type‑V 600‑bar hydrogen pressure tank as well as a doubly curved engine ring structure. IPF develops design and sizing methods, software/CAM interfaces, and a development process–integrated structural validation approach carried out in a virtual–experimental workflow.

IPF-relevant research objectives

Development and enhancement of design and sizing methods for combined variable-axial TFP/FW hybrid structures (including TFP patches and local reinforcement).
Provision of TPF/FW software and CAM interfaces enabling automated (non-)geodesic fiber placement on curved structures (including integration of computed trajectories into real layup processes).
Establishment of a development process–integrated structural validation and exemplary structural proof for ring and tank components.

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF) — Germany
Technische Universität Dresden — Germany
EAST-4D Carbon Technology GmbH,
Hightex Verstärkungsstrukturen GmbH,
IMA Materialforschung und Anwendungstechnik GmbH,
Leichtbau-Zentrum Sachsen GmbH — all Germany.)

Project sponsor

German Aerospace Center (DLR), Project Management Agency Aerospace Research
Funding reference number: 20Q2118E

M-era.net "MBrace"

Multi-Matrix Composites for Fashionable, Customized and Evolvable Braces (MBrace)

Funding period: 06/2022 – 08/2025

MBrace develops innovative, patient-oriented scoliosis braces based on multi-matrix composite concepts. By integrating materials development, manufacturing and design, machine-learning based analysis of patient data, and advanced diagnostic/fitting workflows, the project aims to significantly improve wearing comfort and overall treatment quality. The goal is a lighter, more comfortable, and visually appealing brace with flexible functional regions (e.g., additional bending points), shifting brace therapy from an uncomfortable fixation device towards a supportive and accepted aid.

IPF-relevant research objectives

Develop/optimize multi-matrix composite structures for scoliosis braces and integrate them into manufacturing/process concepts (in particular TFP-based approaches).
Support numerical design and material/structure modeling for brace components (FEA/simulation, design of variable-axial fiber architectures).
Contribute to technical evaluation/validation of the MMC approaches (manufacturing prototype components, providing material/process data for design).

Project partners

Technische Universität Dresden, Institute of Biomedical Engineering (IBMT), Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
SIRRIS, Belgium
Isomatex SA, Belgium
HTW Dresden (Faculty of Design), Germany
UJK Kielce (Collegium Medicum, Jan Kochanowski University of Kielce), Poland

Project sponsor

M-era.net | Call 2021

Find out more Project video

M-era.net "Gradient"

Graded Interphases for Enhanced Dielectric and Mechanical Strength of Fiber Reinforced Composites

M-era.net Call 2021

High-performance composites, composed of reinforcement (fiber, particles, fillers,...) and a matrix, have a large usage in many fields. Particular in power transformers and switchgear its application is responsible for many advantages. In this specific case, the dielectric and mechanical strength is influenced by the fiber-matrix interphase. Since the composite failure, generally, occurs in the fiber-matrix zone, it is critical to develop approaches to reduce stress concentrations in this region.

Development of approaches to reduce stress concentrations in the interphase;
Fiber surface modification;
Graded Interphases (interphase engineering);
New methodologies, validation tools and multi-scale simulation for interphase characterization and optimization.

Project Partners:

Luleå University of Technology (LTU)
University of Latvia (LU)
Hitachi Energy Sweden AB, Composites (Hitachi)

Find out more

ZIM "CFKadapt"

CFKadapt – Development of a Thermoformable Fiber-Reinforced Polymer Composite Material for the Production of Adaptable Orthopedic Devices

Funding period: 08/2021 - 01/2023

CFKadapt develops a thermoformable fiber-reinforced polymer composite material that allows orthopedic braces and prostheses to be adapted to individual patient anatomies after consolidation (“fitting”) with low effort. The project combines (i) development of a new thermoresponsive two-phase polymer matrix system and (ii) integration into a manufacturing process usable by orthopedic technicians. Preforms are produced using the Tailored Fiber Placement (TFP) technology, while dedicated forming zones and a suitable thermal forming process are developed for safe and low-distortion post-adaptation. The developed technologies are validated through demonstrators and patient tests by the end of the project.

IPF-relevant research objectives

TFP-based design and preform development: development of local forming zone concepts, variable-axial / TFP preform structures, and integration of forming segments.
Development and validation of the fiber–matrix composite: practical implementation of the design concept via TFP, development of impregnation and consolidation procedures (together with the orthopedic partner), plus material/component tests.
Mechanical characterization and analysis of the effects of thermoforming: micro-/macromechanical testing and assessment of damage mechanisms after forming.

Project partners

REHA-OT Lüneburg Melchior und Fittkau GmbH — Germany
E.F.M. GmbH — Germany
Fraunhofer IFAM (Fraunhofer Institute for Manufacturing Technology and Advanced Materials Research) — Germany
Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) — Germany
IWS GmbH — Germany

Project sponsor

ZIM Netzwerk fimatec (initiated by the ZIM Netzwerk fimatec)
Funding reference number: 16KN102001

ZIM "Basaltfunier"

Basalt-Fiber Reinforced Veneer-Based Panels – Development of the Process and Technical Solution for Manufacturing Composite Materials from Veneer and Fiber-Reinforced Polymer Composites

Funding period: 03/2021 - 12/2023

The project develops and validates a manufacturing process for basalt-fiber-reinforced veneer-based composite panels in which high-stiffness fiber–polymer composite (FRP/FC) layers are integrated into the edge regions of veneer products. The aim is to improve fire behavior (without adding specific special salts for flame/brand protection) while also enhancing mechanical performance (bending/torsion), potentially enabling thinner and lighter panels for the same stiffness/load requirements. In parallel, an FEM-based numerical simulation model and a practical engineering design tool/software for dimensioning are developed.

IPF-relevant research objectives

Develop a basalt–phenolic resin composite prepreg/half-product and perform numerical simulation-based modeling of the composite material (FEM).
Determine and compile material parameters for simulation of the composite system (fiber–matrix and composite behavior, including dependencies on climate/temperature).
Provide an easy-to-use dimensioning/design software to enable practical stiffness and load capacity assessment without requiring expert-level FEM expertise.

Project partners

Neugersdorfer Holzwerke GmbH — Germany
SAB Stahl- und Anlagenbau GmbH — Germany
Technische Universität Dresden — Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF) — Germany

Project sponsor

Zentrales Innovationsprogramm Mittelstand (ZIM)

ZIM "ProLaMas"

EFFICIENT LIGHTWEIGHT CONSTRUCTION: Fiber Composite Machine Tool Sledge with TFP

Funding period: 01/12/2020 - 31/05/2023

The project develops a novel machine tool carriage for HSC/HPC applications based on variable-axial TFP-CFRP lightweight structures. The goal is a mass reduction of 30–50% while maintaining or improving structural stiffness, enabling higher process speeds and potentially lower drive power. The work includes topology-/fiber design, manufacture of production-oriented TFP preforms, development of an RTM process with tooling, and an in-use component testing campaign. In addition, a methodological assessment of the technological and economic relevance of the innovations is performed.

IPF-relevant research objectives

Development and sizing of variable-axial TFP-CFRP structures using numerical modeling (FEA), including validation calculations considering local fiber orientation and thickness distribution.
Support of the engineering and process preparation, including preform- and simulation-based development steps for industrial implementation.
Thermal analysis and functional component testing/validation of the developed TFP-CFRP structure within the overall system.

Project partners

SW – Schwäbische Werkzeugmaschinen (SW) — Germany
ZAFT – Zentrum für angewandte Forschung und Technologie e.V. — Germany
Leibniz Institute for Polymer Research Dresden e. V. (IPF) — Germany
Schmuhl Faserverbundtechnik GmbH & Co. KG (SCHMUHL) — Germany
Hightex Verstärkungsstrukturen GmbH (HIGHTEX) — Germany

Project sponsor

Zentrales Innovationsprogramm Mittelstand (ZIM)

Industrial Project "ConThiCo"

Consolidation of thick thermoplastic composite parts made by Tailored Fiber Placement

Industrial Project

Successful hot pressing of C-Frame part made out of 16 CF-LEXTER-Preforms (530 g)
Multi-stage structural failure with increasing load maxima in tensile test
Maximum peak force levels similar to CF-epoxy C-Frame with approx. 70% of comparable stiffness

IGF "CoTherMu"

CoTherMu: Development of locally deformable 3D composites from thermoplastic-elastomer multi-matrix systems in complex textile 3D preforms (MM-FKV)

Funding Period: 10/2023 - 03/2026

The project develops a simulation-assisted process chain for manufacturing thermoplastic multi-matrix fibre-reinforced composites (MM-FKV) with solid-state hinges (FKG). The key idea is to locally and reproducibly create stiffness gradients—and thus controllable rotational compliance while maintaining sufficient in-plane stiffness—by integrating hybrid yarns (HG) made of reinforcement fibres (e.g., glass) and thermoplastic matrix fibres with different stiffness levels. Textile technologies are advanced for 2D preforms (TFP) and 3D, tubular preforms (MLG/knitting). Two application-focused demonstrators—orthotics (medical technology) and robotics/grippers (machine building)—demonstrate transferability.

Research Objectives for IPF

Develop and characterize hybrid yarn material systems, especially TPU/GF-HG, including the required online hybrid yarn spinning processes.
Develop and integrate simulation and modelling approaches (material and structural models) enabling the design of functional preforms/fibre paths with local stiffness gradients.
Validate MM-FKV performance through structural/mechanical characterization and support demonstrator realization and KMU-oriented guidelines.

Project Partners

Leibniz Institute for Polymer Research Dresden e.V. (IPF), Germany
Institute of Textile Machinery and High-Performance Textile Materials (ITM), TU Dresden, Germany

Project Sponsor:

AIF: Allianz für Industrie und Forschung

DAAD-PPP/CAPES "FiBraCo"

Fiber Bragg Grating Sensors For The Monitoring Of The Response Of FW+TFP Composite Pressure Vessels

Funding period: 01.01.2024 – 31.12.2025

The project develops a methodology to measure strains under service conditions in Composite Pressure Vessels (CPVs) manufactured by Filament Winding (FW) and locally reinforced with TFP patches. The motivation is the presence of pronounced stress concentration regions (e.g., at mosaic-pattern boundaries and at openings) and the resulting challenge of reliably predicting failure modes. Therefore, numerical (FEM) models and experimental testing are combined with Fiber Bragg Grating (FBG) sensing, enabling real-time structural monitoring and measurements potentially including through-thickness/inter-layer information. The validation is performed step-by-step from 2D TFP-reinforced substructures to instrumented cylinders, and the methodology is extended towards in-service monitoring.

IPF-relevant research objectives

Numerical FEM analysis of CPVs including TFP reinforcement patches, identifying critical stress/strain locations and assessing sensitivity to material and geometric parameters.
Supporting the definition and implementation of the FBG sensor positioning strategy (including possible inter-layer measurements) and validating the approach on 2D substructures and instrumented cylinders.
Contributing to experimental–numerical model validation and transferring the methodology towards in-service applications (failure modes under static/dynamic loading, including fatigue).

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF) — Germany
UFRGS (Federal University of Rio Grande do Sul) — Brazil

Project sponsor

DAAD PPP/CAPES

Completed projects:

AIF Cornet "TailComp"

TailComp – Tailored Fibre Placement in Thermoplastic Composites

Funding Period: 01.05.2016 – 30.04.2018

TailComp develops a resource-efficient technology to manufacture optimized thermoplastic/hybrid composite structures. The core is load-oriented fibre placement (Tailored Fibre Placement / TFP) combined with fibre-path optimization, ensuring an optimal correlation between load case and fibre orientation. To improve economics, the project pursues lower-cost consolidation routes (e.g. vacuum bagging instead of autoclave) and develops lightweight, low-thermal-inertia tooling produced via incremental sheet metal forming (ISF). A key objective is to quantify performance levels between the low-cost process route and high-end autoclave processing.

Research Objectives for IPF

Development of online commingled hybrid yarns (materials and yarn quality): intact reinforcing filaments, tailored fibre volume content, sizing/adhesion tailoring, and improved yarn integrity.
Contribution to TFP preform design and manufacturing for complex 3D parts, including numerical/model-related aspects to enable fibre-path/topology optimization.
Validation of material properties and process-chain relevance (for structural simulation inputs and consolidation/part performance), supporting overall guidelines and demonstration cases.

Project Partners

Forschungsgesellschaft Kunststoffe e. V. (FGK), Germany
Fraunhofer IWU, Germany Leibniz Institute for Polymer Research Dresden e. V., Germany
SIRRIS, Belgium (Wallonia region)

Project sponsor

CORNET | 20th Call

AIF IGF "LoVarMed"

LoVarMED – Simulation-assisted technology for producing load-adapted fibre-based implants with defined, locally varying stiffness gradients

Funding Period: 08/2015 - 10/2017

LoVarMED develops a simulation-assisted manufacturing technology for fibre-based implants with locally tailored stiffness gradients. The approach uses embroidery/stitched fibre placement due to its high flexibility and ability to create load-oriented fibre deposition in a material-efficient way. Using hernia mesh implants as application example, the project aims to realize structures with controlled mechanical properties and cell-friendly functionality. The work includes the development of long-term resorbable chitosan-based yarns with defined degradation kinetics and an additional collagen surface coating. The project integrates chemistry/material development, simulation-based design, manufacturing, and cell biology into a complete process chain.

Research Objectives for IPF

Simulation-based design of load-adapted implants: development/refinement of modelling and design methods for locally varying stiffness fields (including meso-scale modelling of yarn-/structure behaviour).
Contribution to the embroidery manufacturing chain and fabrication of stitched demonstrator patterns for experimental validation.
Development of a stitch pattern generator (software plugin/tool) enabling automatic creation of stiffness-gradient patterns with locally adjustable properties.

Project Partners

Research Site 1: Technische Universität Dresden, ITM, Germany
Research Site 2: Leibniz Institute for Polymer Research Dresden e.V. (IPF), Germany
Research Site 3: Technische Universität Dresden, TFO, Germany

Project sponsor

Forschungskuratorium Textil e.V. (FKT) / DECHEMA

AIF "Kleinquerschnitte"

Process development for reinforcing statically and dynamically highly stressed small cross-sections made of wood and wood-based materials using fibre-reinforced plastics (FRP)

Funding Period: 01.01.2009 – 31.12.2010

The project aims at developing a new, reproducible technology for producing wood/wood-based composite components reinforced with FRP for statically and dynamically highly loaded small cross-sections. The motivation includes limitations in reliable timber grading and the lack of verified knowledge on long-term static and dynamic composite performance. A one-step process is targeted in which FRP is embedded in/at the wood cross-section and bonded simultaneously. Additionally, FE simulation models for design support will be developed and validated using functional prototypes.

Research Objectives for IPF

Development and determination of material parameters needed for simulation and composite assessment (including experimental acquisition of missing properties, e.g. basalt fibre).
Support of test and characterization schemes to quantify static and dynamic short- and long-term characteristics under defined climate conditions.
Contribution to FE model development and validation against bending tests (including optical deformation measurements) and derivation of design guidelines.

Project Partners

Technische Universität Dresden (TUD), Germany
Leibniz-Institut für Polymerforschung Dresden e.V., Germany

Project promoter

AiF (Alliance for Industry and Research)

BMBF "BIOTEX"

BIOTEX – Bionic design and textile manufacturing processes for cost-efficient production of optimized fibre-reinforced composite structures

Funding Period: 07/2004 - 08/2008

The project develops bionically inspired calculation and design methods together with textile manufacturing processes to produce cost-efficient, end-contour-near optimized fibre-reinforced composite structures. The aim is to tailor fibre orientation and reinforcement geometry so that loads are introduced more uniformly and the full lightweighting potential is realized. Technological implementation is pursued via new/advanced textile preforms (including 3D tailored fibre placement, fibre spraying, multiaxial textiles and braiding) and adapted binder-/process concepts. The feasibility and economic value are validated in demonstrators across multiple application fields.

Research Objectives for IPF

Material-technical fundamentals for bionic composite structures: determination of static and especially dynamic mechanical properties (e.g., stiffness degradation and residual strength) for TFP, MAG, carbon-fibre spraying and braided structures.
Testing concepts and experimental characterization at specimen and component level (flat samples/demonstrators), including comparison with simulation results.
Contribution to deriving design guidelines for bionic structures (e.g., load introduction zones, openings, I-beam-like configurations) and support of demonstrator assessment with a focus on dynamic testing.

Project Partners

European Aeronautic Defence and Space Company (EADS), Germany
DaimlerChrysler AG, Germany
Fr. Lürssen Werft, Germany
Institute for Aircraft Construction – Stuttgart, Germany
Institute for Polymer Research Dresden, Germany
Institute of Statics and Dynamics – Stuttgart, Germany
Forschungszentrum Karlsruhe, Germany
Ingenieurbüro Moldenhauer, Germany
Keilmann Sondermaschinenbau Lorsch, Germany
Saertex Wagener, Germany
SINTEC Keramik GmbH & Co KG, Germany
August Herzog Maschinenfabrik, Germany
Volkswagen AG (VW), Germany
Wacker Polymer Systems, Germany

Project sponsor

Funding program of the BMBF (now the BMFTR)

BMBF "highSTICK+"

Functionalized Prepreg - joint project within the growth core “highSTICK plus”

Funding Period: 01.09.2012 – 31.08.2015

The overall goal of the VP 4 consortium is the development of a manufacturing technology for functionalized prepregs with load-adapted, matrix-preimpregnated reinforcement fibers and integrated functional elements. The approach extends embroidery-based fiber placement towards Tailored Prepreg Placement (TPP): prepreg rovings are deposited in a process-reliable and reproducible manner on embroidered bases or on preimpregnated base materials. The technology is intended to reduce/eliminate the subsequent resin infiltration step compared to comparable TFP processes and enables the integration of sensors/actuators directly during manufacturing.

Research Objectives for IPF

Characterization of material- and process-related aspects of matrix-impregnated intermediate products for embroidering/prepreg processing (including curing/process windows).
Development and testing of a lab-scale roving impregnation system and manufacturing of reproducible prepreg rovings with a defined fiber volume fraction.
Support of numerical/material design and evaluation tasks: structural-mechanical design, assessment of specimens (mechanical/microscopic) and derivation of design/process guidelines.

Project Partners

Dietrich Wetzel KG, Germany
Leibniz Institute for Polymer Research Dresden, Germany
KSA GmbH & Co. KG, Germany
Sächsisches Textilforschungsinstitut e.V. (STFI), Germany
IFC-Composite GmbH, Germany

Project sponsor

Funding program of the BMBF (now the BMFTR)

BMBF "EMIR"

EMIR – Use of TFP (Tailored Fiber Placement) for the manufacturing of stringers/frames (spants) (Omega and Z frames) for fuselage structures

Funding Period: 2003 – 2007

The EMIR project aimed to prove that TFP can be used to produce fiber-aligned, fuselage-relevant frame structures in a low-cost manner. The approach was successfully demonstrated for Omega frames and Z frames. For infiltration of the 3D TFP preforms, an electrically heated composite tool with an integrated carbon roving resistance heating structure was developed and manufactured. Qualification was performed via material characterization (coupon tests) and the production of demonstrator preforms and frames.

IPF Research Objectives

TFP-based preform and frame manufacturing, including optimization of the layup (e.g., “interleaved” ±45° structures) for Omega and Z frames.
Development of an electrically heated composite tool using an integrated carbon-fiber resistance heating concept, including heating element design/controls and temperature homogeneity.
Characterization & validation of prepreg vs. TFP structures through coupon testing (tension/compression), followed by infiltration (e.g., VAP) and demonstrator production.

Project Partners

Airbus Bremen (AG), Germany
Hightex Verstärkungsstrukturen GmbH, Germany
Leibniz-Institut für Polymerforschung Dresden e.V., Germany

Project sponsor

BMBF - Federal Ministry of Education and Research, now: BMFTR - Federal Ministry for Research, Technology and Space

Find out more

DAAD "PROBRAL"

DFG priority program 1123 (''Schüttgutbecher'')

Development of strength-optimized biaxial knitted preforms for complex geometries: Design, manufacturing, and testing of a biaxially reinforced glass fiber-reinforced plastic (GFRP) bulk material hopper.

The project is part of the Priority Programme (SPP) 1123 titled "Textile Composite Materials and Manufacturing Technologies for Lightweight Structures in Mechanical and Automotive Engineering". The research project aims to systematically develop the fundamental engineering principles for the load-path-optimized design of textile preforms and components. Additionally, it focuses on creating textile-adapted manufacturing technologies, consolidation processes, assembly techniques, and tooling systems. Using selected technology demonstrators from mechanical and automotive engineering, the project exemplifies innovative approaches for the load-appropriate development of textile-reinforced composite structures in lightweight design.

Purpose

Design and construction of a double-shell tool for the injection of a 3D preform made from biaxial knitted fabric with variable wall thicknesses.
Development and manufacturing of an electrically heatable injection mold made from fiber composite materials.
Development of a manufacturing technology for producing the bulk material hopper.
Production of bulk material hoppers using different versions of the biaxial knitted fabric.

DFG "MerVa"

Methods and Process Development for the Infiltration of Highly Loaded Topology-Optimized Fiber-Reinforced Polymer Components with a Variable-Axial Fiber Architecture (MerVa)

Funding period: 2019 - 2022

The MerVa project aims to establish a systematic process understanding for the infiltration of load-bearing variable-axial Tailored Fiber Placement (TFP) structures. For these structures, flow and filling behavior is currently neither sufficiently predictable nor reliably designable. Therefore, FAST and IPF develop and validate multi-scale simulation approaches (micro–meso–macro) and complement them with experimental permeability measurements and imaging-based analyses. The goal is a solid basis for the subsequent design and optimization of the manufacturing process for TFP components.

IPF-relevant research objectives

Experimental determination of permeability and the inhomogeneous material structure of TFP-UD preforms (in particular the influence of stitching thread path and fiber volume content (FVG)).
Quantification of fiber and resin distribution using polished-section images and CT/µCT to parameterize meso models.
Development/enhancement of meso structure and generator models (including reconstruction of the stitching thread path) as a basis for scaled simulations.

Project partners

Institut für Fahrzeugsystemtechnik, Lehrstuhl für Leichtbautechnologie (FAST), KIT, Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany

Project sponsor

German Research Foundation(DFG)

DFG "OptiTex"

DFG "Kreuzbandersatz"

Tissue Engineering of an Anterior Cruciate Ligament (ACL) Graft Based on Resorbable, Stitched Scaffolds: Development of a Hybrid Structure Consisting of a Biomechanical, a Biointegrative and a “Vital” Unit

Funding period: 02/2012 – 01/2015
Continuation/extension period for IPF and FILK: 02/2015 – 01/2017

This project develops an ACL hybrid construct combining stitched, resorbable scaffold components with a “vital” unit based on cells and naturally produced ECM. The goal is a mechanically robust entheseal-like interface zone (bone–cartilage–ligament) including functional cell barriers. Material and stitching design, collagen infiltration, pore/template architectures, and mechanostimulation are optimized and evaluated in a dynamic nude mouse model and finally in an orthotopic rabbit ACL model.

IPF Research Objectives

Scaffold design & stitching technology: integration of collagen barriers and engineering a longitudinally oriented pore structure (template/lost core and/or collagen hollow fibers).
Material/degradation studies: assessment of scaffold filament degradation under cell culture conditions (mechanical/chemical/structural).
Provision/characterization of stitch-ready scaffold variants for in‑vitro and in‑vivo experiments, including selection of melt-spun PLA filaments.

Project Partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Forschungsinstitut für Leder und Kunststoffbahnen gGmbH (FILK), Germany
Klinikum Nürnberg Medical School GmbH, Germany
Paracelsus Medizinische Privatuniversität (PMU), Germany

Project Sponsor:

German Research Foundation (DFG)

EU "EMBROIDERY"

EMBROIDERY – Development of energy efficient / lightweight composite parts and tooling based on Tailored Fibre Placement technology / self heating technology

Funding period: 01/2011 – 12/2012

Project summary (max. 4 lines) The EMBROIDERY project develops self-heating layers embedded into composite rigid tooling and/or flexible membranes using Tailored Fibre Placement (TFP) technology. The goal is a more energy-efficient and faster manufacturing route (especially for OOA/prepreg and infusion-related processes) and improved process robustness through monitoring and automation. In parallel, algorithms are developed to exploit TFP’s fibre steering capability in design-oriented software tools for composites.

IPF-relevant research objectives

Development and extension of FEA-based modelling approaches and failure criteria for TFP composite parts with curvilinear, non-uniform fibre paths.
Theoretical verification and comparison of optimization strategies, plus derivation of guidelines for simplified generic structural elements.
Development of an industrial deployable AOPS design tool version to support TFP fibre steering in practical/commercial workflows.

Project partners

Fundación INASMET – Tecnalia (INASMET / INAS), Spain
Institute for Aircraft Design (University of Stuttgart / USTUTT), Germany
Leibniz Institute of Polymer Research Dresden (IPF), Germany
GMI Aero (GMI), France
Ingenieria y Desarrollos en Composite (IDEC), Spain
Mandiola Composites (MANDI), Spain
Avana (AVANA), Hungary
Tajima (TAJIMA), Germany
Q-Point Composite (QPOINT), Germany

Project Sponsor

European Union: Seventh Framework Programme (FP7)
Grant Agreement No.: 262355

FNR "HoBaCo"

HoBaCo – Development of wood veneer–basalt fibre composites for structural fire-safety applications

Funding Period: 10/2019 - 09/2022

The project develops and optimizes a hard-to-ignite hybrid composite made of hardwood veneers and fibre-reinforced polymer (FRP) composites reinforced with textile basalt fibre structures for structural fire protection. The aim is to achieve a significant reduction of component thickness and mass in both the construction and vehicle sectors while meeting mechanical, acoustic and fire-safety requirements. An (partly) bio-based phenolic resin is used as matrix, requiring the development of a compatible fibre sizing/adhesion strategy for basalt fibre–matrix bonding. Material characterization and simulation are performed including the effect of temperature and relative humidity. By the end of the project, a demonstrator will be produced and tested comparatively (static, vibration/acoustic, and fire properties).

Research Objectives for IPF

Develop/optimize the material system and basalt fibre textiles, including sizing and fibre–matrix adhesion (basalt fibre to phenolic resin).
Contribute to numerical simulation/FEM modelling of stiffness and deflection improvements, incorporating climate-dependent experimental findings into model updates.
Support the overall benchmarking and validation of mechanical/acoustic and (as applicable) fire-relevant properties through preparation of key material parameters.

Project Partners

Leibniz Institute for Polymer Research Dresden e.V. (IPF), Germany
Technische Universität Dresden – Institute of Natural Materials Technology, Germany
Fraunhofer Institute for Applied Polymer Research IAP, Germany
Pagholz Formteile GmbH, Germany
Deutsche Basaltfaser GmbH, Germany
EBF Dresden GmbH, Germany

Project sponsor:

Fachagentur Nachwachsende Rohrstoffe e.V.

SAB/EFRE "Carbonstickgrund"

Development of a new technology for the production of load-bearing tailored reinforced nonwovens from recycled carbon fibres

Funding Period: 04/2018 - 03/2020

The project aims to develop and qualify nonwoven stitch bases for Tailored Fiber Placement (TFP) made from recycled carbon fibres (rCF). The goal is to produce nonwovens that do not require a binder and still provide sufficient integrity for a process-stable roving fixation step. In addition, hybrid nonwovens with thermoplastic staple fibres (rCF-TP) are addressed to cover both duromer and thermoplastic matrix systems, reducing material use and costs.

IPF Research Objectives

Adaptation of the TFP process to enable process-stable roving fixation on rCF and rCF-TP nonwovens, including definition/evaluation of permissible stitch parameters (target: > 500 stitches/min).
Development of a thermoplastic sewing thread (same polymer as the thermoplastic component in rCF-TP) to improve process coupling and to compensate for roving waviness through melting during consolidation.
Consolidation and fabrication of test specimens using duromer and thermoplastic matrix systems, including determination of necessary consolidation conditions (temperature/pressure/time) and development of a subcomponent and demonstrator to demonstrate performance.

Project Partners

Sächsisches Textilforschungsinstitut e.V. (STFI), Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany

Project sponsor

SAB - Sächsische Aufbaubank

SAB "NGScope"

Next Generation Endoscopy Scopes (NGScopes): Actuator Development Based on Shape Memory Alloys (SMAs) and Polymer Composites

Funding Period: 01.02.2020 – 31.03.2022

The project develops a scalable actuator platform for a new generation of endoscopic instruments. The core technology is Shape Memory Alloys (SMAs) integrated into a mechanically structured polymer sheath, combined with control electronics, interfaces, and modular coupling of active components (e.g., optics). The aim is to build a functional prototype (minimal viable system, MVS) up to TRL 5, focusing on precise long-term control, user-centered operation, and regulatory preparation. This is intended to overcome key limitations of conventional cable-driven endoscopes, especially hygiene-related issues.

Research Objectives for IPF

Materials & composite development: Design and fabrication of a “hybrid muscle” (SMA integration into suitable polymer composite/latching concepts) to ensure precision and long-term stability.
Scalable manufacturing/processing routes for actuator structures (e.g., co-extrusion, coating/composite variants, potentially precision welding), including mechanical and thermal characterization.
Mechanical system integration suitability: Support in selecting/testing materials and in developing contact and mounting concepts for integrating the actuators into the endoscope/instrument system.

Project Partners

Prof. med. Jochen Hampe | Director of the Department of Internal Medicine 1, Gastroenterology & Hepatology; Prof. Dr.-Ing. Andreas Richter | Chair of Microsystems Engineering, Faculty of Electrical Engineering and Information Technology, Technische Universität Dresden, Germany
Dr.-Ing. Axel Spickenheuer | Leibniz Institute for Polymer Research Dresden, Germany
Contronix GmbH, Germany
WOLFRAM Designer and Ingenieure, Germany

Project sponsor

SAB - Sächsiche Aufbaubank

SMWK "Orbita"

Orbita - Stitch-based processing of ultrafine titanium wires for the development of patient-specific, shapeable orbital floor implants

Funding Period: 07/2019 - 06/2021

The project aims to develop a new, partially resorbable orbital floor implant for reconstructing orbital defects. The concept uses a flexible, resorbable polymer carrier that is locally reinforced by ultrafine titanium wires (commercially relevant titanium grades such as pure Ti and TiAl6V4) applied via stitching/technical embroidery. The reinforcement layout should enable a drapable, modelable, and trimming-friendly implant design without cutting through the metal wire. The work is based on material/process evaluation, design generation from imaging data, and mechanical testing/validation.

IPF Research Objectives

Classification and evaluation of titanium wires (pure Ti/TiAl6V4, varying diameters and surface treatments) with respect to sewability/embroidability (including suitability for TFP and conventional two-thread embroidery).
Assessment of resorbable base materials (membranes, nonwovens, foils) as potential stitch substrates, including contingency optimization (e.g., heat-soluble stitch bases to create pure wire patterns).
Design, fabrication, and testing of embroidered implant variants: converting CT/DVT image information into stitch pattern data, characterizing morphology and mechanics, developing a test setup, and producing demonstrator models.

Project Partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Charité – Universitätsmedizin Berlin (associated partner), Germany

Project sponsor

SMWK - Saxon State Ministry for Science, Culture and Tourism

ZIM "AniDo"

AniDO – Practical development of a design and manufacturing process suitable for Tailored Fiber Placement (TFP) using advanced anisotropic topology optimization

Funding Period: 07/2019 - 06/2021

The project develops an end-to-end process chain for variably axial fiber reinforced polymer (FRP) structures using Tailored Fiber Placement (TFP). Anisotropic topology optimization is used to automatically generate fiber path data which is translated into TFP preforms. In addition, TFP equipment, consolidation tooling, and a demonstrator part are developed and tested to prove industrial suitability.

IPF Research Objectives

Develop an automated tool for fiber path/fiber design generation based on anisotropic topology optimization results for TFP fabrication.
Perform further optimization of fiber placement, including cross-sectional optimization and DFPO (Direct Fiber Path Optimization), and assess mechanical performance.
Numerical and experimental verification of the approaches, including evaluation of the impact of technical constraints.

Project Partners

Tokai Industrial Sewing Machine Co., Ltd (TISM), Japan
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Kyoto University (Uni Kyoto), Japan
AT Gesellschaft für technische Realisierung im Bereich Bootsbau und Kunststofftechnik mbH (AT), Germany
TRUMPF Schweiz AG (TRUMPF), Switzerland

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand

ZIM "TFPprint"

TFPPrint – Tailored Fiber Placement Technology Extension with an Elastomer Print Head for Partial Infiltration of Textile Preforms

Funding period: 01/12/2018 – 31/01/2021

Within the TFPPrint project, a new manufacturing technology is developed to enable novel fiber-reinforced multi-matrix components. Based on Tailored Fiber Placement (TFP), reinforcement fibers are laid variably-axially and predefined zones are then infiltrated with elastomeric material using a newly developed elastomer print head—for example to create hinge/function zones. Additionally, direct printing of material onto the preform shall be possible (e.g., padding or other functional elements). The approach is validated using demonstrators from the orthopedic field, requiring significant hardware and software innovations for the TFP system.

IPF research objectives

Develop/extend the TFP process chain for the elastomer print head, enabling zone-wise elastomer impregnation and multi-matrix manufacturing.
Design and build demonstrators, including variable-axial preform structures and their consolidation into components.
Process-preparation at CAM/control level, integrating the required parameters and data for fiber placement and elastomer deposition.

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF) — Germany
Technische Universität Dresden, Institute for Precision Engineering and Electronic Design , Germany
E.F.M. GmbH Entwicklung Fabrikation Marketing, Germany
MOUNTEK GmbH, Germany
REHA - OT Lüneburg Melchior und Fittkau GmbH, Germany

Project sponsor

AiF Projekt GmbH (ZIM)
Funding reference number: ZF4028414PO8

ZIM "FlexOr"

CFK lower-leg–foot orthosis with a novel return-spring element (FlexOr) and automated patient-specific manufacturing using Tailored Fiber Placement (TFP)

Funding Period: 07/2017 - 06/2019

The project aims to develop a novel lower-leg–foot orthosis (AFO) made from carbon fiber reinforced polymer (CFK) with a scalable return-spring element and patient-specific automated manufacturing via Tailored Fiber Placement (TFP). It integrates digital capture (3D scan/CAD), automated TFP fabrication of carbon-fiber preforms, and downstream consolidation/processing into functional orthosis products. In parallel, material and process requirements as well as testing/validation approaches are established.

IPF Research Objectives

Design and development of a scalable return-spring element, including spring behavior and energy recovery analysis, supported by parametric simulation models.
CAD-based fiber pattern / feed data generation and process-near data preparation for CNC-controlled TFP manufacturing for patient-specific requirements.
Material testing, component testing and mechanical validation of the developed orthosis/spring-element variants, including derivation of boundary conditions for test methods.

Project Partners

Reha-OT Luneburg Melchior & Fittkau GmbH, Germany
Embro GmbH, Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand

ZIM "Hotflex"

HotFlex – Development of multifunctional elastomer heating caps for thermal binder activation processes with complex geometry

Funding Period: 01/2016 - 12/2017

The project develops a novel, reusable electrically heated elastomer vacuum-cap system for binder activation / preforming of fiber-reinforced composites with complex 3D geometries. Using an integrated electrothermal heating system with locally controllable heating zones—combined with additional functional integration (reinforcement, actuators, sensors)—the goal is to significantly reduce cycle time, improve contour accuracy, and increase service life/stand time. The system is targeted for use up to 180 °C and aims at industrial applicability (including aviation).

IPF Research Objectives

Materials research: selection support, characterization, and qualification of elastomer/composite materials for heated caps (temperature/chemical/mechanical durability, shrinkage, crack sensitivity).
Functional integration: development and evaluation of sensor and actuator mechanisms (particularly piezo-based actuation/sensing) at component/sub-system level, assessing long-term suitability.
Testing/validation: characterization and validation of performance (e.g., deformation, thermal behavior, pressure sensing), including service-life tests and derivation of quality evidence for scale-up.

Project Partners

Qpoint Composite GmbH, Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany

Project sponsor

ZIM- Zentrale Innovationsprogramm Mittelstand

ZIM "Holz-FKV-Verbund"

ZIM "Membranpresse"

Development of an innovative membrane press for more efficient manufacturing of fiber composite components from thermoplastic semi-finished products for small and medium production series

Funding period: 01/2020 - 06/2022

The project develops a novel membrane press for efficient manufacturing of thermoplastic fiber composite parts in small to medium series. The aim is to achieve faster and more energy-efficient processing via IR-based heating and an overpressure/vacuum process concept (5–10 bar). Key innovations are a high-temperature membrane, an IR heating concept including zoning, and a cost-effective polymer-concrete forming tool with low thermal conductivity and modular tooling capability.

IPF Research Objectives

Develop and qualify a high-temperature membrane (silicone/elastomers), including thermal degradation assessment and determination of required material properties (thermal conductivity, heat transfer, heat capacity, IR absorption).
Build a FEM/analytical simulation model of the process chamber thermodynamics and optimize the heating strategy, accounting for interactions between membrane, tool and semi-finished part under pressure and IR exposure.
Develop an integrated heating conductor system within the membrane (carbon-fiber or wire-based, e.g., meander-shaped) to enable contour-/zone-adapted heating, and verify effects on drapability and thermo-mechanical stability.

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Technische Universität Dresden, Institut für Leichtbau und Kunststofftechnik (ILK), Germany
Franz Fischler GmbH & Co. KG, Germany
Wickert Maschinenbau GmbH, Germany

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand

ZIM "WintFlap"

WIntFlap - Development of a fluid-technically actuated movable trailing-edge flap for wind turbine rotor blades and a test facility for a 3‑m test section

Funding period: 04/2015 - 03/2017

The project develops a compact hydraulically actuated system for movable trailing-edge flaps integrated into wind turbine rotor blades, targeting robustness, lifetime, maintainability, and lightning protection. A 3‑m trailing-edge flap demonstrator will be developed and validated in realistic long-duration tests covering load cycles, actuation behavior, and maintenance concept. Aerodynamic design, structural integration, the hydraulic actuator system, and an elastic film-hinge joint concept are developed and experimentally validated.

IPF Research Objectives

Material & joint development: Development of a CFRP/elastomer composite film hinge as an elastic bending joint for flap attachment, including design of the bending line and critical laminate stresses.
Simulation & dimensioning: FE-/AOPS-based design for variably axial fiber concepts plus determination of required material parameters (including climate/UV effects).
Manufacturing & validation: Fabrication of joint specimens (via TFP preforms and vacuum infiltration) followed by static and cyclic/dynamic tests to assess strength and durability; design of the joint variant for the demonstrator.

Project partners

cp.max Rotortechnik GmbH & Co. KG, Germany
WINDnovation Engineering Solutions GmbH, Germany
Technische Universität Dresden – Institute of Fluid Mechanics (IFD), Germany
Leibniz Institute for Polymer Research Dresden e. V. (IPF), Germany

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand

ZIM "10k-Tool"

Novel CFK tools with long service life (“10K-Tool”)

Funding period: 10/2012 – 04/2015

The project aims to develop electrically heated injection tools for the RTM process made from fiber-reinforced composite (FRP) materials. The concept includes carbon-fiber heating structures and robust, wear-resistant surface/material systems. For industrial applicability, the target is up to 10,000 moldings and high dimensional tolerances under thermal and mechanical service conditions.

IPF Research Objectives

Materials and surface development for wear-resistant CFRP tool surfaces (including coatings/gelcoat/harz system selection and durability optimization).
Numerical simulation of the tool’s mechanical and thermal behavior (FE modeling with integrated heating structure).
Testing & validation: development of an application-relevant surface test method and validation of simulations using optical deformation measurement (ARAMIS) and thermography, resulting in a design guideline for the 10K tool.

Project Partners

Hightex Verstärkungsstrukturen GmbH (Hightex), Germany
EAST-4D Carbon Technology GmbH (East4D), Germany
Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Qpoint Composite GmbH (Qpoint), Germany

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand

ZIM "Development of a highly centrifugal force loaded rotor"

Constructive implementation of lightweight design principles using endless fibers arranged in a load-direction-oriented, 3D manner (demonstrator: torque support)

Funding Period: 04/2011 - 03/2012

The project develops a demonstrator component (torque support) with a variably axial fiber architecture based on endless glass-fiber reinforced thermoplastic (GF‑PA6/66 hybrid rovings) to achieve significant mass and performance improvements versus reference components (aluminium and short-glass fiber thermoplastics). The concept combines structural-mechanical design (fiber paths aligned with principal stress directions) with manufacturing of the preform via Tailored Fibre Placement (TFP) followed by press consolidation/densification and downstream processing by the industrial partner.

IPF Research Objectives

Materials & process: Determine reproducible conditions for producing online-spun GF‑PA6/66 hybrid rovings, including process window, fiber/polymer distribution and effects such as shrinkage.
Design & manufacturing integration: Use/extend anisotropic FE-based design approaches (notably AOPS) to derive fiber paths and generate corresponding TFP/embroidery feed data.
Preform manufacturing & consolidation: Produce high-quality TFP preforms (stick/machine parameter optimization) and consolidate them using appropriate tooling and process parameters, including quality assessment (porosity, laminate quality).

Project partners

Leibniz-Institut für Polymerforschung Dresden e. V. (IPF), Germany
Weberitwerke Dröbing GmbH, Germany
Technology-Institut für Metall & Engineering GmbH, Germany

Project sponsor

ZIM - Zentrale Innovationsprogramm Mittelstand