Fraunhofer IFAM

Upscaling painted release films for the sustainable production of tomorrow

Description of the company

Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM is part of the Fraunhofer-Gesellschaft, the world’s leading applied research organization. In Stade we develop solutions for automated assembly, joining and machining technologies. We work on projects mainly for the aircraft and wind power industry. Our focus lays on the topics of large structure assembly, adhesive and surface applications, innovative lightweight materials, production-related prototyping, robotic systems, process optimization, digital factory planning and metrology devices.

Situation

Prepreg and in-mould coating are pivotal in the production of modern and sustainable composite aircraft structures. Prepreg, a composite material pre-impregnated with resin, offers superior strength-to-weight ratios, crucial for enhancing fuel efficiency and performance. Its consistent quality and ease of use streamline manufacturing processes, reducing production time and costs. In-mould coating, applied during the moulding process, ensures a high-quality finish, excellent durability, and resistance to environmental factors. This integration minimizes post-production steps and enhances the aerodynamic properties of the aircraft. Together, these advanced materials and techniques are essential for developing lighter, more efficient, and resilient aircraft of the future.

Problem

Chemical release agents, while essential for preventing composite materials from sticking to moulds, present several challenges. These agents often leave residues on both the mould and the produced parts, necessitating extensive cleaning procedures. The residues can interfere with subsequent manufacturing steps, such as painting, bonding, or coating, compromising the quality and performance of the final product. Additionally, the cleaning process itself can be labor-intensive, time-consuming, and involve the use of harsh chemicals that may pose environmental and health risks. Therefore, finding alternatives or improving current release agents to reduce residue is crucial for enhancing efficiency and safety in composite manufacturing.
To overcome this problem, the Fraunhofer IFAM has developed a plasma polymer-coated PeelPLAS® release film which can be painted in a roll-to-roll process. This painted release film can currently only be produced and painted up to a width of approx. 4m.

Aims of the project

Combining two painted release films effectively addresses gaps between the foils and painting layers, ensuring a seamless finish in composite manufacturing. These gaps, if left unaddressed, can lead to surface imperfections, weak points, and aesthetic inconsistencies in the final product. By filling these gaps, manufacturers can achieve a uniform surface that enhances the structural integrity and visual appeal of the composite parts. This process also optimizes the bonding and coating applications, resulting in higher quality and performance standards. Employing this technique is crucial for producing flawless and durable composite materials, especially in high-precision industries such as aerospace and automotive manufacturing.

•    Achieve an airtight combination of both films
•    Maintain the thickness of the combined film
•    Keep the joint seam between the foils smooth
•    Filling the gap between the layer of paint
•    Measure film layer thicknesses

Scopes

The development process should cover the following point:

• Research of the state of the art thin film combination, in-mould coating and paint application
• Identification of sub-problems and requirements e.g:
  • Combining of two or more thin films
  • Paint application on the film
  • Measurement technology
• Investigation of possible technologies for the implementation of sub-solutions
• Concept development for an automated system
• Pre-test series
• Simulation/Visualization of the final system

Target group (students)

We are looking for a committed, open minded and interdisciplinary team in which everyone can contribute with their expertise and would like to do some hands-on work. Your field of study might be:

• Systems engineering of e.g. aircrafts, renewable energies, automotive, ships
• General Engineering Science
• Product development, Materials and Production
• Materials science
• Mechanical engineering
• Mechatronics
• Robotics

Bachelor students are very welcome.

If your course of studies is not listed, don’t worry, this list is not exhaustive. Feel free to apply.

Dates
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Registration
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