Press releases

To ensure the quality of recyclates, the Fraunhofer Institute for Structural Durability and System Reliability LBF is planning a new joint research project with partners from industry to optimize polyolefin recyclates for sustainable solutions. New analytical methods and user-friendly evaluation strategies should enable cost-efficient quality control and improvement of recycling processes. The project promotes the transformation into a circular economy and invites partners to collaborate. More information will be provided in a free online seminar on May 6, 2025.

Users of poly- and perfluorinated alkyl compounds (PFAS), also known as "forever chemicals", are under pressure due to regulatory proposals from the European Chemicals Agency (ECHA). This also affects the use of fluoroelastomers, whose economic significance is enormous. Fraunhofer experts initiated the "HATE-Fluor" project at the beginning of February. Together, they want to develop high-performance elastomer compounds to replace fluoropolymers in certain technical applications. Various industries can benefit from this, including manufacturers of semi-finished and finished parts as well as companies in mechanical engineering industry, medical engineering, clean room and semiconductor technology, chemical process technology and electrical applications.

The development of high-quality, halogen-free flame retardants (hffr) for recycled plastics to meet increasing recycling quotas is a major challenge. The Fraunhofer Institute for Structural Durability and System Reliability LBF is looking for partners for the new project "hffr-Up2Cycle". The main objective of this project is to upgrade PCR materials with halogen-free flame retardants (hffr) and to investigate these materials through the simulation of closed-loop processes for plastics containing flame retardants in the sections of electronics, automotive, construction and cable applications. The project is aimed at OEMs, manufacturers of plastic components, raw material suppliers, compound developers and industry associations.

Current bio-based plastics are limited to short-life applications, such as packaging, as they have insufficient long-term properties. The new project "Bio-based polyesters for demanding long-term applications" by Fraunhofer Institute for Structural Durability and System Reliability LBF aims to improve the long-term properties of biopolymers through tailored additivation enabling their use in technical applications. Therefore, the researchers are looking for partners along the value chain that would like to substitute petro-based plastics with bio-based solutions for durable products.

Hydrogen fuel cells are a promising solution for the future of electric mobility, especially in the commercial vehicle industry. But how can the challenges associated with their implementation be overcome while increasing the efficiency and reliability of these technologies? Fraunhofer researchers will share the latest findings and approaches from reliability assessment in an online event on April 15.

To ensure Germany remains competitive as a location for the foundry industry, the German Foundry Association (Bundesverband der Deutschen Gießerei-Industrie e.V. - BDGuss has recently outlined several measures, including reducing energy costs, conserving resources, reforming environmental legislation, and achieving climate neutrality. Therefore, the interdisciplinary congress for high-performance cast components "InCeight Casting C8" will take place from March 5 to 6, 2025 combining experts and decision-makers from the foundry industry to exchange ideas on design and product development, structural durability, non-destructive component testing, casting technology and simulation - with the aim of developing high-performance and sustainable components. The program and registration are now available online.

The mechanical recycling of plastics faces several challenges, both technical and regulatory. From a technical point of view, there are questions about the availability of recyclates, ways to improve the quality and evaluation of recyclates, and its long-term properties in demanding applications. From a regulatory perspective, there is a need to comply with and develop regulations and guidelines, increase recycling rates, and promote recycling technologies. These challenges require innovative approaches and close cooperation between industry, research. and politics. The 7th "Forum Plastic Recyclates" on March 26 and 27, 2025 in Darmstadt will address these issues, in context of mechanical plastics recycling, and has established itself as an important industry meeting platform with a high degree of practical relevance. The conference program and online registration are now available.

All organic substances, including plastics such as polypropylene (PP), undergo auto-oxidation in the presence of oxygen. This happens millions of times faster at the high temperatures of compounding and injection moulding. The result for PP is a degradation of the polymer chains, i.e. a reduction in molecular weight, which means that products made from these plastics can no longer be recycled. Antioxidants added during the manufacturing process slow down this degradation. Without these additives, many everyday objects could not be produced in a usable form. Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have further improved the rheological online tests so that the exact additives can be determined more quickly, and the costs optimised.

At a time when environmental sustainability is paramount, recyclates are of central importance in industry. Due to EU regulations and waste reduction targets, their use has increased significantly. However, a major challenge is to ensure that post-consumer recyclates meet safety standards, especially in terms of flame retardancy. Upgrading with effective halogen free flame retardants is essential. Teams of experts at the Fraunhofer Institute for Structural Durability and System Reliability LBF are working intensively on EU regulations and the need for halogen free flame retardancy in specific applications. The focus is on technical and strategic considerations from which many industries can benefit. Fraunhofer LBF will present the results at the Plastics Recycling Show Europe, Amsterdam, June 19-20, 2024, booth A22.

Lithium-ion batteries from electric vehicles lose their charging capacity during the use. Therefore, they are no longer suitable for vehicle operation from a ca-pacity loss of 20 percent, as the range and fast-charging capability are reduced. However, the remaining capacity of 80 percent is sufficient for a stationary storage application. In the CIRCULUS research project, several Lithium-ion trac-tion batteries already in use are being converted into a stationary storage sys-tem. The innovative lightweight design of the overall system ensures that the system can be dismantled according to type. This minimizes the sorting effort, resulting in high-quality material flows and thus implementing a functional and sustainable circular economy. Fraunhofer LBF will be presenting the results of the CIRCULUS research project at the Plastics Recycling Show Europe, Amster-dam, June 19-20, 2024, booth A22. Visitors will gain a comprehensive insight into Fraunhofer LBF's wide-ranging expertise in recyclates.

For the first time, the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE will present the topic ‘Sustainable Geosynthetics for Landscaping’ at ACHEMA 2024 alongside the topic ‘Advanced Recycling’. We cordially invite you to visit us at the trade fair in Frankfurt (Hall 6.0 – Research and Innovation | Booth D49).

The energy crisis, material shortages, lack of skilled workers and inflation are limiting the competitiveness of the German foundry industry. There is a great need to produce more efficiently and sustainably. In addition to digitalization, efficiency increases can be driven forward in particular through increased networking between those involved in the development process from industry and research. The international congress "InCeight Casting C8", from March 5 to 7, 2025 in Stockstadt, Germany, offers this interdisciplinary exchange of knowledge and interests for the third time with in-depth specialist presentations, workshops and panel discussions with the aim of learning from each other and thus remaining fit for the future.

With their high chemical and thermal resistance, metal cushions are a sensible alternative to elastomer components. The elasticity and damping of the wire mesh is based on the interaction of individual wire segments during deformation - a mechanism that is also reflected in the change in electrical properties. Researchers at the Fraunhofer Institute for Structural Durability and System Reliability LBF have harnessed this effect in the form of a new sensor concept. The new sensor technology can be integrated into existing systems in a cost-effective and space-neutral manner and directly detects vibrations and loads. Processes and bearing conditions can be monitored and dynamic bearing forces quantified with simple means. Applications in vehicle and mechanical engineering as well as in measurement and testing technology are conceivable

Challenges in the mechanical recycling of polycarbonate, opportunities for circular design in the automotive industry or the question of whether there are enough recyclates of appropriate quality for all users - these and more will be the topics of the sixth Forum Plastic Recyclates on March 13 and 14, 2024 in Darmstadt. This event offers expert knowledge on topics such as additivation and stabilization, analysis of recyclates, masterbatches and compounds as well as applications. The conference program and online registration are now available. The new #LBFDeepDive format answers questions from an exclusive group of participants.

In recent years there have been major changes in the life cycle testing of vehicles or individual components: Thanks to state-of-the-art testing technology today a few hours in the laboratory are sufficient for life cycle testing whereas previously test drives on the road taking a couple of weeks were necessary for this purpose. This development continues as the UC 16 -Users Conference on Biaxial Wheel/Hub Fatigue Testing on November 8th, 2023, in Darmstadt showed. More than 50 scientists and users from Europe and all around the world met at the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt. Thanks to a wide range of development and testing activities in the field of wheel testing and approval, the institute was able to establish itself as a technology leader. Today the testing technology is known and accepted on a worldwide basis. It has been established as the international standard for more safety in vehicle wheels construction. Besides it shortens the development times for new reliable and safety relevant products.

innovations for the technical supply industry Lightweight design makes products competitive and sustainable. Safety and reliable function must be guaranteed in the process. Promising new approaches for sustainable and efficient manufacturing processes with natural fiber-reinforced materials and the lightweight design potential through vibroacoustic metamaterials are shown by the exhibits from the Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt at the "Highly advanced materials for a circular world", November, 14 to 16, 2023 in Jönköping/Sweden, ELMIA Subcontractor, Area: InnoDex, Hall D. The fair is a meeting point for decision makers, constructors and designers of the manufacturing industry in Northern Europe.

The use of recycled plastics is becoming increasingly popular due to its potential to reduce the environmental impact of plastic waste. However, the quality of recyclate materials significantly affects their application. With the exception of slightly damaged production waste, recycled plastics cannot be used in their original form. Usually, they are sorted, cleaned, and reprocessed to form usable granules. However, the recycled material's stability and processing ability for its intended application often require post-stabilization with suitable additives. Fraunhofer Institute of Structural Durabiity and System Reliability LBF has developed new formulations for enhance the quality of new recyclate films. At Plastics World Expo Europe, Essen, June 14-15, 2023, Booth C834, the researchers will give more information.

Elastomeric materials are used in the automotive industry, the construction sector, and many other applications. These are to become more environmentally friendly. The Fraunhofer Institute for Structural Durability and System Reliability LBF in Darmstadt is bringing together companies to provide insights into the requirements for tomorrow's rubbers in the online workshop "Sustainable Elastomers" on June 20, 2023. Additives and rubber raw materials as well as the analytics and characterization of rubbers will be highlighted. Participants will discuss the challenges of developing and using sustainable additives and fillers, as well as the opportunities and technical approaches to compounding, applying, and recycling sustainable elastomers.

Plastic materials are prone to degradation by atmospheric oxygen. These auto-oxidation reactions occur at ambient temperature already but become especially relevant during melt processing. Adding antioxidants to the polymers results in a pronounced slowing-down of the oxidation processes. Only by this way, the production of the well-known plastic parts by injection moulding, for example, is possible. Developing new plastic grades is accompanied by lengthy experimental procedures to optimize the antioxidant content. Researchers at Fraunhofer Institute for Structural Durability and System Reliability LBF see online rheological investigations as a promising method for accelerating the development process.

What doesn't smell good is hard to recycle. This simple rule also applies to the growing volume of plastic waste worldwide. One way to recycle it in an environmentally compatible and climate-friendly manner as high-quality post-consumer recyclates is through improved sorting and reprocessing. Until now, the reduced material quality has considerably limited the reuse of plastic recyclates, and this is mainly due to their odor. Scientists at the Fraunhofer Institute for Structural Durability and System Reliability LBF have developed a new environmentally friendly process on a laboratory scale to remove odors from plastic packaging. Fraunhofer LBF will present the results of the research project at the Plastics Recycling Show Europe PRSE, Amsterdam (May 10 to 11, 2023, Hall 11, Booth P3) and at Plastics World Expo Europe, Essen (June 14 to 15, 2023, Booth C834).