idw – Informationsdienst Wissenschaft
Nachrichten, Termine, Experten
Nachrichten, Termine, Experten
idw - Informationsdienst
Wissenschaft
At the beginning of March, the third funding period commenced for the Open Hybrid LabFactory (OHLF) research campus, which is funded by the German Federal Ministry of Education and Research (BMBF). In collaboration with Volkswagen, the Technische Universität Braunschweig, the Fraunhofer Center Circular Economy for Mobility CCEM, Ostfalia University of Applied Sciences and 35 further partners, practice-oriented and efficient solutions for a sustainable circular economy in the automotive industry are being developed at the OHLF within the scope of this funding phase.
For this purpose, the BMBF is providing a funding volume of ten million euros, which will cover three major research projects and a duration of five years. A central component of this initiative is the “CirProTech” project, the kick-off meeting for which took place in Wolfsburg at the end of March.
Successful start for “CirProTech”
For the kick-off meeting of the BMBF project “CirProTech”, representatives of the eight industrial partners and the three research institutes came together. Following an introduction of the participating partners and their objectives, the approximately 30 participants were given a tour of the OHLF technical center. They were thereby provided with insights into the infrastructure and technical and analytical possibilities that are available for the development of recycling processes and the qualification of components made from recyclate. In subsequent workshops, initial demonstrators for the closed-loop recycling of plastic and CFRP components in the automotive and aerospace industries were identified. Parallel to this, requirements for materials and processes as well as analytics were established, which serve as the basis for the development. “The kick-off meeting was an important first step towards creating a common understanding of the challenges and potential of the project,” emphasized project coordinator Dr. Michael Thomas, Head of Department at the Fraunhofer Institute for Surface Engineering and Thin Films IST and Head of the Fraunhofer CCEM. “The intensive collaboration between all the partners lays the foundation for innovative and practicable solutions - from the development and qualification of materials, through recycling processes, and all the way to the utilization of the recycled materials.”
Next steps: Evaluation and development of sustainable processes
Based on the initial workshop results, various potential plastic and CFRP components are now being selected as material sources, appropriate recycling paths are being investigated, analyzed and evaluated, and initial samples are being produced. A catalog of requirements is thereby being created that defines the technical specifications for parts and components in accordance with the respective recycling cycle. In order to ensure ecological and economic sustainability, extensive plant and material data is also being collected and consolidated within data models. “Our goal is to develop sustainable circular processes throughout the entire life cycle of plastic and CFRP components that are not only ecologically but also economically viable,” summarized Dr. Thomas.
About the “CirProTech” project
The goal of the “CirProTech” project is the development of technological solutions for closed-loop reutilization processes for components made from plastics and carbon-fiber-reinforced plastics (CFRP).
The focus is hereby formed by two application cases: the recycling of plastics for the construction of new automotive components, and the recycling of CFRP structures for utilization in the aerospace industry. A particular challenge lies in the separation of materials that are often glued, pressed or fused with other materials. Through the development of new processes, it should be possible to obtain high-quality recycled materials that offer a viable alternative to primary materials, both economically and ecologically. By switching to closed-loop production processes, companies will be able to not only reduce their raw-material consumption and CO2 emissions, but to also take advantage of new economic opportunities. The “CirProTech” project is therefore providing an important contribution to the transformation towards a sustainable, resource-conserving industry.
The successful implementation of the project relies upon the close cooperation of all 11 partners, each of whom pursue their own priorities and objectives. The specific project objectives of the participating partners are presented below:
The Fraunhofer IST is working on the development and investigation of an energy-efficient microwave pyrolysis process for the recycling of CFRP components with optimum preservation of the mechanical fiber properties. Furthermore, the Fraunhofer IST is investigating efficient paint-removal techniques – based on laser and flash irradiation – for plastic components. In addition, through surface functionalization by means of plasma, an adhesive coating of new components made from recyclate should be made possible.
Through the development and application of data-based methods and innovative detection and evaluation technologies, the TU Braunschweig aims to acquire a comprehensive understanding of the recycling process chains of plastics and fiber-reinforced plastic composites in order to evaluate and improve their economic and ecological sustainability within the framework of a holistic circular economy.
The Institute of Machine Tools and Production Technology IWF at the TU Braunschweig is responsible for the evaluation and processing of thermoplastics and recyclates for a sustainable, data-based circular economy. In particular, the ecological sustainability of production is to thereby be addressed.
The aim of the Institute of Joining and Welding ifs at the TU Braunschweig is to further develop and integrate innovative detection and evaluation methods for the holistic analysis and optimization of plastic components, in order to ensure their quality and suitability for recycling processes and subsequent production steps.
Volkswagen is addressing the issue of increasing efficiency in the closed-loop recycling of plastics through improved separation, sorting and recycling processes as well as optimized product design. This is crucial in order to fulfill current and future legal requirements, such as the recycling rate of 30% and the application of PCR materials, as well as to achieve internal sustainability goals.
The work being carried out by Tailorlux GmbH focuses on the development and implementation of advanced detection and marking methods for the quality assurance of recyclates, which establish cross-industry standards through the recognition of chemometric characteristics and the application of chemical markers in automated recycling processes. As a result, the possibility arises in the field of material detection to meaningfully extend NIR measurements by means of VIS data – without markers – in order to detect specific additives, for example.
RTT System GmbH is working on the development and standardization of an automated system for the precise detection and evaluation of plastics, which increases the efficiency and accuracy of material analysis through the utilization of innovative sensors. For this purpose, RTT is developing a measuring cell that scans the surface of the object for the best possible analysis points, thereby enabling a differentiated analysis and downstream sorting of the objects.
The goal of Invent GmbH is to research the manufacturing processes of CFRP components such as tanks or pipes made from recycled carbon fibers with application-relevant properties. To achieve this, a guideline for action is being developed in which key factors such as design aspects, process requirements, material properties and recyclability for the realization of components made from recycled fibers are recorded.
Fricke und Mallah Microwave Technology GmbH is responsible for the industrial microwave technology used in the CirProTech research project. The objective is to significantly expand the range of applications for microwave technology, and to extend the product portfolio to include recycling systems.
SBS Sondermaschinen GmbH is developing a test facility for automated fiber recovery. The process is to be used for wound CFRP components, such as for tanks or pipes. The sub-goals are to integrate microwave pyrolysis and in-situ analysis of recovered fibers into the system. The acquired specialized knowledge will allow systems for applying the new technology to be systematically dimensioned, scientifically analyzed and further developed into new products.
POLYTEC Plastics GmbH & Co. KG is a leading developer and manufacturer of high-quality plastic solutions. The company offers innovative products for various sectors, including automotive, commercial vehicles and new mobility concepts. Polytec’s project goal is the further development of plastic components made from recyclates with a high closed-loop content by means of a demonstrator component in order to transfer the project results to other sustainability issues relating to materials and components.
DOMO Engineering Plastics Europe S.p.A. Germany is working on the production and qualification of high-quality polymer recyclates made from PCR materials and closed-loop materials for mono- and multi-material components in the automotive sector. The project results can be transferred to the products already established at DOMO, thereby supporting DOMO’s sustainability strategy in the long term. DOMO’s aim is to develop high-quality products with PCR content in order to offer its customers solutions that enable the achievement of the ambitious sustainability goals and requirements.
https://www.ist.fraunhofer.de/en/press-media/2025/kick-off-fuer-cirprotech.html?...
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