TRR 402:  Intelligent production technologies for lightweight plastic structures with load-dedicated 3D grading of the reinforcement architecture

• Subject Area: Mechanical and Industrial Engineering
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 525069572

Future technology and product developments will be measured by the increase in resource efficiency for sustainable climate protection with a significant reduction in greenhouse gas emissions. In order to implement the necessary measures in mobile applications, lightweight construction technologies for the largescale production of low-mass components have a particularly broad impact. Accordingly, the main objective of the planned SFB/TRR is to research mechanisms of action for the fusion of plastic-based technologies for the production of lightweight structures that exhibit load-dedicated 3D grading of the reinforcing structure. The research work focuses on combination technologies of compossible in-line and in-situ pro-duction processes that are characterised by their suitability for large-scale production, in particular injection moulding and pressing. The main focus is on transitions between continuous and discontinuous fibre reinforcement. Based on a coupled simulation and multi-criteria optimisation, the hybridisation of such processes and structures requires a targeted adaptation of material, geometry and process parameters. As part of the CRC/TRR, the so-called elementary profile structure component (EPS) and the elementary flat structure component (EFS), which are being investigated in the basic injection moulding and pressing production groups, serve to provide technological proof of the calculated and optimised grading in the FRP/plastic transition area. The focus is on the analysis and control of the processes for the gentle integration of the locally and globally graded semi-finished products and for the process-inherent modification of the fibre architecture. The data required to quantify the environmental impact of fibrereinforced plastic constructions must be supported by the introduction of product life cycle management from the design phase onwards. This is made possible by storing all the necessary data and parameters along the entire value chain, from the requirements to the geometry, material properties and process conditions through to the structural behaviour. It is crucial that the necessary parameters are identified from a life cycle assessment perspective and harmonised with the sub-projects in order to support a holistic approach. Advanced methods based on new approximation strategies are being developed for research into intelligent compostable production technologies. Comprehensive processing of data and models from the design, analysis, production and recycling processes is necessary to allow appropriate feedback into a centralised intelligent development and pro-duction system (iDP system). Based on a catalogue of requirements for a lightweight structure and predefined optimisation criteria, the iDP system generates the best possible solutions.

• DFG Programme: CRC/Transregios
• International Connection: Austria

Current projects

• A01 - Multi-criteria optimisation of in-situ reorientation processes for defined graded profile structures (Project Heads Klärner, Matthias ;  Kroll, Lothar )
• A02 - High-volume production of individualised, graded and variantrich laminates for combined manufacturing chains (Project Heads Brecher, Christian ;  Emonts, Michael )
• A03 - Injection moulding embedding of locally functionalised fibre-reinforced plastic inlays (Project Heads Kroll, Lothar ;  Roth-Panke, Isabelle )
• A04 - Press processing of functionalized flat and tape substructures with a flanged section (Project Heads Lasagni, Andrés Fabián ;  Modler, Niels )
• A05 - Adaptive models for in-line process monitoring and control (Project Heads Dementyev, Alexander ;  Ihlenfeldt, Steffen )
• B01 - Adaptive production of components with locally definable adjustment of the fibre architecture (Project Head Hopmann, Christian )
• B02 - Influencing fibre orientation by means of process-integrated actuators (Project Heads Drossel, Welf-Guntram ;  Pagel, Kenny )
• B03 - Electromagnetic alignment of reinforcement elements (Project Heads Lampke, Thomas ;  Winkler, Anja )
• B04 - Dedicated edge zone characteristics for pultruded fibre-reinforced polymer and ceramic profiles (Project Heads Drossel, Welf-Guntram ;  Roder, Kristina )
• B05 - Pultrusion of semi-finished products with graded properties using recy-clates from plastic waste streams (Project Heads Fischer, Kai ;  Greiff, Kathrin )
• C01 - Simultaneous optimisation of geometry and graded fibre orientation distributions (Project Heads Ihlemann, Jörn ;  Wulf, Hans )
• C02 - Integrative numerical design methods for component and process (Project Heads Behr, Ph.D., Marek ;  Elgeti, Stefanie )
• C03 - Model reduction and formalisation for increased efficiency of integrative simulation chains (Project Heads Hopmann, Christian ;  Schön, Malte )
• C04 - Methodical derivation of process-structure-property-relations based on hy-brid data spaces (Project Heads Gude, Maik ;  Tzortzinis, Georgios )
• C05 - Generative design for actively controlled mould systems with high system complexity and functional density (Project Heads Ihlenfeldt, Steffen ;  Krahl, Michael )
• C06 - Collection and context-sensitive distribution of process data (Project Heads Brecher, Christian ;  Fey, Marcel )
• C07 - Product Lifecycle Management and Life Cycle Assessment for Eco-Design (Project Heads Greiff, Kathrin ;  Paetzold-Byhain, Kristin )
• Z01 - Verwaltungsprojekt (Project Head Kroll, Lothar )

• Applicant Institution: Technische Universität Chemnitz
• Co-Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen; Technische Universität Dresden
• Participating Institution: Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik (IWU); Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik (IWU) ; Wissenschaftsbereich Umformtechnik
• Participating University: Technische Universität Wien
• Spokesperson: Professor Dr.-Ing. Lothar Kroll