FUNCTIONAL STRUCTURES STRUCTURING ADVANTAGES INTEGRATING FUNCTIONS

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1 F R A U N H O F E R I N S T I T U T e F O R M A N U FA C T U R I N G A N D A D VA N C E D M AT E R I A L S I FA M FUNCTIONAL STRUCTURES STRUCTURING ADVANTAGES INTEGRATING FUNCTIONS

2 C O N T E N T F U N C T I O N A L S T R U C T U R E S 3 P R I N T E D E L E C T R O N I C S A N D S E N S O R S I N K T E L L I G E N T P R I N T I N G 5 S I M U L A T I O N A N D D E S I G N 6 H Y B R I D M A T E R I A L S A N D N A N O C O M P O S I T E S 7 N A N O P O R o u S F U N C T I O N A L I T Y F o R A D V A N C E D E N E R G Y A P P L I C A T I O N S 9 O U R S E R V I C E S 1 0 WE UNDERSTAND MATERIALS T H E F r a u n h o f e r - G e s e l l s c h a f t Practice-oriented research and development is the principal task of the Fraunhofer-Gesellschaft. Founded in 1949, the research organization performs applied research and development for the benefit of economy and society. The customers and contractual partners of the Fraunhofer- Gesellschaft are industrial enterprises, service providers and public authorities. At present, the Fraunhofer-Gesellschaft operates 60 research institutes with a total staff of 17000, the majority of whom are qualified scientists and engineers. S H A P I N G A N D F U N C T I O N A L M A T E R I A L S The Shaping and Functional Materials Division of the Fraunhofer Institute for Manufacturing and Advanced Materials IFAM, with its facilities in Bremen and Dresden, develops innovative materials and adapts and improves existing manufacturing processes. Our R&D work ranges from material engineering, shaping and manufacturing technologies to functionalizing components and systems. We develop individual solutions for customers in various industrial sectors including automotive industry, medical technology, aviation and aerospace, mechanical, electrical and environmental engineering, as well as the electronics industry. Our offer includes component design and optimization, computer simulation of shaping processes as well as technical implementation in the industrial production and providing the related training for customer staff. Our R&D activities on functional materials deal with improving the properties and processing of materials. Functional materials can either be directly integrated into components during the manufacturing process or applied later by printing or sputtering them onto the components surfaces. They provide additional or completely new characteristics, for example electronic or sensory functions. Cellular materials have special properties that are in demand for energy absorption, noise absorption and heat exchangers. Additional research focuses on biomaterials made from metals, ceramics or polymers and their biological interaction with the environment. Based on these two areas of expertise, we are expanding into the new application field of electric mobility, with a special focus on energy storage and electrical power trains. Analyzing, testing, evaluating and optimizing the complete system is the main objective of our work. In the area of shaping the focus is on the cost- and resourceefficient production of increasingly complex-shaped, or miniature precision components. Using innovative manufacturing processes in both powder and casting technology, we give additional functionality to components. Fraunhofer - Institut für Fertigungstechnik und Angewandte Materialforschung IFAM Formgebung und Funktionswerkstoffe 2

3 FUNCTIONAL STRUCTURES Next to shaping, the functionalization of a component is the most important criterion in determining its future use. Functional materials, such as suspensions, composites or cellular coatings, equip components with additional or entirely new properties. Intelligent functionalization Depending on the individual application, the functional materials are structured in a customized way and are integrated into the component or applied to its surface. However, in many applications, making the best decision about an innovation is complicated by the numerous variants according to which functional materials may be structured. New and improved methods, a wide range of applications and the variety of materials available demand comprehensive knowledge to work with the corresponding technologies. The department of Functional Structures at Fraunhofer IFAM has gained extensive experience in this domain, focusing on (nano-) composites, nanoporous layers, printed electronics and sensors. Our interdisciplinary team works in cooperation with our customers to develop the concepts for functional integration, combining the materials and manufacturing processes. To implement the integration of functions in manufacturing, various technologies, such as 3D printing, ink-jet printing, aerosol printing and screen printing, as well as sputtering and compounding methods and extrusion are available. Know-how and technology transfer Based on the results of feasibility studies, the technologies are transferred and integrated into industrial manufacturing processes in cooperation with our customers. This process may also involve the engineering of customized special equipment on a laboratory or pilot production scale. Contact: Dr. Volker Zöllmer Phone ifam.fraunhofer.de 3

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5 1 2 PRINTED ELECTRONICS AND SENSORS INKtelligent printing Functional integration by means of printed structures: Potentials for packaging as well as for»intelligent components«. Flexibility thanks to INKtelligent printing The technology platform INKtelligent printing is aimed at developing printing processes and printable functional materials, as well as functional structures for industrial applications. Fraunhofer IFAM has access to a wide variety of printing technologies in order to guarantee the customers requirements in terms of desired function, material, substrate, structural size or batch size. Depending on the goal, it is possible to adapt the material to be printed either to a certain printing procedure or to a special substrate. The next step is the formulation of the printable»ink«suitable for the chosen printing technology. To do this, we at Fraunhofer IFAM have available the technology for the necessary treatment and supervision of quality. In principle, any type of material polymers, ceramics or metals - may be used. Thermal activation of the printed structure is frequently necessary and can be accomplished using a furnace or by means of a laser, in a microwave oven or through UV hardening. Large figure: Miniaturized printed temperature sensor. Figure 1: The heart of an aerosol printer also suitable for»complicated«inks. Figure 2: Evaluation of ink-jet printing of functional materials. Possible application areas for the use of INKtelligent printing : Bonding and 3D PCB tracks for packaging Metallic temperature or fill level sensors, as well as strain gauges Gas sensors based on printed metal oxide semiconductor materials Printed OLED or solar cells»invisible«and thermally stable marking as protection against plagiarism Biosensors created by combining printed electronics with biologically active substances 3D printing of metallic components or individual implants Contact INKtelligent printing : Dr. - Ing. Dirk Godlinski Phone ifam.fraunhofer.de Marcus Maiwald Phone ifam.fraunhofer.de 4 5

6 1 2 SIMULATION AND DESIGN Figure 1: Consultation and demonstration of simulation results. It is possible to optimize not only the individual geometry of a printed sensor, but also its placement on the component. Figure 2: Numerical stress simulation of a strain gauge. Simulation and design of printed sensors To tap the full potential of printed sensors, it can be extremely helpful to make use of simulation methods. At Fraunhofer IFAM, the sensor structures are dimensioned according to the requirements and constraints of the planned application. Furthermore, the use of printed sensors, e. g. in structural health monitoring, also determines the optimal position of a sensor on the component surface. To do this, in addition to classical numerical simulation by means of Finite Element Method (FEM), we also use optimization methods, for example, Design of Experiments (DOE), Response Surface Modeling (RSM) and Robust Design. The flexibility of mask-free application methods means that the results from simulation and design may be immediately transferred to the components. Contact: Andreas Burblies Phone ifam.fraunhofer.de Examples of simulating printed sensors: Sensor dimensioning with regard to detecting mechanical component loads Sensor integration on surfaces sensitive to temperature or hybrid materials Optimization of signal-noise characteristics Positioning of sensors on a component by simulating the component loads and robust design Optimized position and orientation of a printed strain gauge 6

7 1 2 HYBRID MATERIALs and NANOcOMPOSITEs Composites or hybrid materials combine the widest possible variety of material characteristics, such as high conductivity and flexibility. Polymer metal hybrid materials Materials like these combine the advantages of both material classes: They may be processed as granules using commercially available machine and plastic processing systems, and they have the conductivity of a metal, as well. PCB tracks may be applied to surfaces by means of hot-melt technology. By injection molding, electrically conductive moldings are produced; moreover, the hybrid materials can be processed by 2-component injection molding to interlock with other materials. Examples of use for polymer metal hybrids: Seals and electrical bonding Protection of plastic components from static charge or lightning protection Figure 1: Plastic granules containing antibacterial nanomaterials, ready for injection molding. Figure 2: A new hybrid material: As flexible as rubber, as conductive as metal. Contact hybrid materials: Arne Haberkorn Phone ifam.fraunhofer.de Nanoscale filler materials and nanocomposites The production and treatment of extremely fine metallic powders in the size range below 0.1 µm is one of the core competences at Fraunhofer IFAM. To achieve an optimal use of the physical and technical properties, ultrapure, long-term stable nanosuspensions are formulated. Dispersion of nanoparticles and suspensions in polymers and their subsequent compounding open up the opportunity to transfer the nanomaterials into easy-to-handle composites, which may then be processed using established manufacturing technologies, such as injection molding. Examples of uses for the nanosuspensions and composites mentioned above: Metallic and alloy inks for printed electronics Electrolytes based on ionic liquids Antibacterial life science or medical products Corrosion-resistant metallic polymer composites for heat exchangers Contact nanocomposites: Prof. Dr. Bernd Günther Phone ifam.fraunhofer.de 7

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9 1 2 NANOPOROUS FUNCTIONALITY FOR ADVANCED ENERGY APPLICATIONS Customized structures of nanoporous thin films enable highly selective and active catalytic reactions. Customized porosity The homogeneous nanoporous coatings on planar or structured surfaces that are required for these applications may be applied by physical deposition processes in a vacuum (physical vapor deposition, such as magnetron sputtering, gas flow sputtering). Fraunhofer IFAM has many years of experience in the deposition of customized highly porous thin films of ultrapure metals, metallic alloys or ceramics. Process variants, such as co-sputtering, in which two materials are processed simultaneously, and reactive sputtering, in which material is transformed by the addition of a reactive gas, are options that greatly extend the range of materials and applications. Large figure: Plasma in a special equipment for manufacturing highly porous thin films. Figure 1: Detail of a highly porous catalytic film. Figure 2: Nanostructured sputtered thin films on silicon wafer. Examples of use for porous functional layers: Large-area catalytically active coatings even on structured surfaces Selective coatings in channels of filters or microreactors Photocatalytically active coatings for the degradation of contaminants Functional films for solar cells Electrodes for fuel cells Special equipment The transfer of processes developed at Fraunhofer IFAM is also supported by the engineering of customized special systems. We develop and build turnkey equipment and facilities tailored to special materials, semi-finished products and coatings, on a laboratory or pilot production scale. Contact Sputtering: Torben Seemann Phone ifam.fraunhofer.de 8 9

10 1 2 Our Services Figure 1: Treatment of functional materials in a ball mill to obtain printable inks. Figure 2: Turnkey pilot unit for the sputtering of functional materials in liquids. Fraunhofer IFAM offers support, cooperation and services in research and development, as well as transfer of know-how, in the following technological domains: Conceptual design and installation of systems to produce, deposit and process nanoscale powders and suspensions Characterization of nanoscale powders and suspensions (particle size distribution, technological and chemical properties, rheology) Development of functional inks for various printing processes Engineering of special nanocomposites (medical engineering, electrical and power engineering) Feasibility studies for functional integration into series components as well as integration of the corresponding process sequences in existing process chains Choice and modification of an adequate printing process Engineering of new printing processes for customized components and for functional integration Manufacturing of components with complex geometry made of powder-like materials using 3D printing Comprehensive materialography and film characterization by means of SEM, TEM and XRD in an accredited lab We are a team of scientists and engineers with an interdisciplinary orientation, and we see ourselves as your contact partners for solving different problems. It is a pleasure for us to develop concepts and ideas to manufacture your products and components everything, of course, strictly confidential. 10

11 Our Competence SHAPING AND FUNCTIONAL MATERIALS w w w. i fa m. f r a u n h o f e r. d e Fraunhofer Institute for Manufacturing and Advanced Materials IFAM Managing Director Prof. Dr. - Ing. Matthias Busse Phone ifam.fraunhofer.de Biomaterials Technology Prof. Dr. - Ing. Kurosch Rezwan, Dr. - Ing. Philipp Imgrund Phone ifam.fraunhofer.de Processing and characterizing of biomaterials; injection molding, extrusion and micro-structuring of metals, bioceramics, polymers and nanocomposites. Electrical Systems Dr. - Ing. Gerald Rausch Phone ifam.fraunhofer.de Electric mobility; electric vehicles; E-motor-test stand up to 100 kw; test stand for batteries up to 50 kwh; driving cycle analysis; determination of cruising range; system evaluation of electric powertrain. Functional Structures Dr. rer. nat. Volker Zöllmer Phone ifam.fraunhofer.de Nanocomposites; nanosuspensions; nanoporous layers; Functional integration; INKtelligent printing : ink-jet-printing and aerosol printing; hybrid materials; specialty equipment. Materialography and Analytics Dr. - Ing. Andrea Berg Phone ifam.fraunhofer.de Failure analysis; examination of metallographic micrographs; Powder characterization; scanning electron microscopy with EDX analysis; thermal analysis; dilatometry; trace analysis; emission spectrometry. Powder Technology Dr. - Ing. Frank Petzoldt Phone ifam.fraunhofer.de Powder-metallurgical shaping; metal powder injection molding; process- and material development; rapid manufacturing; laser sintering; screen printing; production processes for metal foam components (FOAMINAL ); simulation. D r e s d e n B R A N C H L A B Powder Metallurgy and Composite Materials Prof. Dr. - Ing. Bernd Kieback Phone Winterbergstraße Dresden Cellular Metallic Materials Dr. - Ing. Günter Stephani Phone ifam-dd.fraunhofer.de Fiber metallurgy; high-porosity structures; metallic hollow sphere structures; open cell PM foams; screen-print structures. Casting Technology Dipl. - Ing. Franz-Josef Wöstmann Phone ifam.fraunhofer.de Zinc, aluminium and magnesium pressure diecasting; cast iron and cast steel; cast parts with integrated function (CAST TRONICS ); lost-foam processes; simulation; rapid prototyping. Sinter and Composite Materials Dr. - Ing. Thomas Weißgärber Phone ifam-dd.fraunhofer.de High temperature materials; nanocrystalline materials; materials for tribological exposure; sputter targets; materials for hydrogen storage. 11

12 w w w. i fa m. f r a u n h o f e r. d e Fraunhofer Institute for Manufacturing and Advanced Materials IFAM Shaping and Functional Materials Wiener Strasse Bremen Germany Phone Fax ifam.fraunhofer.de Managing Director Prof. Dr. - Ing. Matthias Busse Functional Structures Dr. Volker Zöllmer Phone ifam.fraunhofer.de Fraunhofer - Institut für Fertigungstechnik und Angewandte Materialforschung IFAM Formgebung und Funktionswerkstoffe