Sustainability in production

Durability, reusability, and a smaller environmental footprint are no longer just customer expectations – they are already mandated by regulation. The European Union’s Circular Economy Action Plan and Ecodesign Regulation are raising the bar for sustainable products and manufacturing processes.

At the same time, companies are expected to ensure environmental and social standards throughout the entire supply chain – from raw material sourcing to end customers. The German Supply Chain Due Diligence Act requires thorough documentation and proactive measures to mitigate environmental risks and uphold human rights. These sustainability goals are understandable, but where and how should companies begin implementing them?

And beyond the mandatory regulations, it is important to remember: sustainability should not be an end in itself – it can be economically beneficial for your business.

From obligation to opportunity: sustainability as a competitive advantage

Identify promising technologies early on and rethink your business models. We start with strategy and innovation management and work with you to uncover technological potential that will help make your business competitive and resilient in future markets.

Finding the needle in the haystack with the right data

One of the major hurdles in transitioning to sustainable production is data quality. Often, the level of detail, measurability, and timeliness required for meaningful environmental assessments is lacking. This makes reliable sustainability evaluations more difficult.

At the same time, the sustainability reports required by the Corporate Sustainability Reporting Directive (CSRD) often lack the detail needed to identify specific technological improvements and to design effective process controls.

We know where production data is generated, how to collect it efficiently, and how to leverage it through collaborative data spaces and digital twins.

Which paths do you want to take?

Let us take you on the road to the resource-efficient, ecologically sustainable and climate-friendly production of the future.

Fields of action for sustainable manufacturing

These four capabilities are essential if your goal is to act with ecological, social, and entrepreneurial responsibility in the future. We’ll show you how to combine sustainability with efficiency and profitability.

 

Green innovations

Get to know sustainable business models and find out how you can use them to further diversify your products and services.

 

Key figures and LCA

Gain transparency about the actual costs of your production.

Hydrogen for energy and mobility

With our research, we are helping to enable the automotive, aviation and energy sectors to make widespread use of hydrogen technologies.

Scalable production of battery technologies

Battery systems are the key technology for climate-neutral mobility. We support the development and transfer of innovations to the “gigafactory” of tomorrow.

Green Production implemented: Methods and Results of our Sustainability Projects

Low-temperature Epitaxy: 90 percent less energy required, 100 percent fewer toxic gases

Resource-saving semiconductor production and energy-efficient consumer goods

In the “GREEN EPITAXY” research project, we are working with our project partners to develop a process chain for the production of WBG semiconductors. The subject of the research is low-temperature epitaxy (NTE): the process temperature is lowered from more than 1000 degrees to 300 degrees by using an intelligent plasma. The use of process gas and energy can be reduced by around 90 percent compared to conventional processes without compromising the crystal quality. Toxic gases can even be dispensed with completely.

Aim: A new production process for semiconductors in Europe

The aim of the project is to create the scientific basis for establishing low-temperature epitaxy as a standard process for the production of wide-bandgap semiconductors. With its expertise in laser and automation technology as well as glass forming, the Fraunhofer IPT is developing the building blocks for the success of the project across the entire process chain. The Fraunhofer IPT's contributions range from the pre-processing of wafers by laser structuring to the automation of processes and downstream process steps such as encapsulation.

Reducing the CO2 footprint in production with additively manufactured components

Environmentally friendly and material-saving hybrid production in metal processing

In the EU project “DIAMETER”, we are working with international partners from industry and research on hybrid production systems for a circular economy in the metalworking industry. The integration of additive manufacturing and supplementary milling technology in a hybrid production system enables the particularly material-saving and circular production of metal components.

Aim: Production without long distances

One aim of the project is to reduce the CO2 footprint in production: By additively manufacturing components on site at the company instead of producing and transporting them centrally, spare parts production can be simplified and transportation routes reduced.

The layered material structure in additive manufacturing allows sophisticated component geometries with cavities and intricate structures to be produced. This can reduce material waste and enables a high degree of design flexibility in component construction. Design criteria such as durability, reparability and recycling are already the focus of the project during the development of components and make it possible to design the entire life cycle of the end product in the sense of a circular economy.

Ecological footprint reduced by 50 percent

Quantifying the environmental impact of alternative manufacturing processes in the aviation industry

In the EU project “Clean Sky 2”, researchers at the Fraunhofer IPT applied the LCA to engine components for aviation and thus determined the resource and energy consumption in various phases of the product life cycle. Sustainability indicators of production and process chains make it possible to quantify the impact of alternative manufacturing processes, determine their efficiency and evaluate the use of “green materials”. Based on the choice of materials and tools as well as the machining strategy, up to 50 percent of the ecological footprint can be saved in the milling process.

Methods

  • Definition of alternative process chains for engine components such as integral compressor rotors (“blisks”)
  • Collection of data on energy and resource consumption along the process chain
  • Impact assessment of alternative products and process routes

Results

  • Reduction of the ecological footprint including the carbon footprint by 30 to 50 percent for milling processes based on material selection, machining strategies and tool selection.

Good to read:
Our publications on sustainability and resilience

In our scientific publications, we have dealt intensively with topics such as sustainability and resilience. Here we make the results of our research work available to you in a condensed form and free of charge.

Jahr
Year
Titel/Autor:in
Title/Author
Publikationstyp
Publication Type
2024 Novel Methodology for Assessing Second Life Potentials of Industrial Products
Schuh, Günther; Schauss, Marc Nicolas; Mikosch, Miguel
Konferenzbeitrag
Conference Paper
2024 Assessing the Environmental and Economic Impact of Wire Arc Additive Manufacturing
Derra, Thomas; Belghith, Khouloud; Gräfe, Stefan; Day, Robin; Bergs, Thomas
Vortrag
Presentation
2024 Life cycle analysis results for engine blisk LCA
Fricke, Kilian; Bergs, Thomas; Ganser, Philipp; Seimann, Martin
Zeitschriftenaufsatz
Journal Article
2024 Konzept für die strategische Planung von Produkttechnologien für die wertsteigernde Kreislaufwirtschaft
Schuh, Günther; Jacobi, Johanna
Konferenzbeitrag
Conference Paper
2023 Empower Green Production. Conference proceedings
Tagungsband
Conference Proceeding
2023 Virtual Experiments for a Sustainable Battery Cell Production
Krauß, Jonathan; Ackermann, Thomas; Kies, Alexander; Roth, David; Mitterfellner, Miriam
Konferenzbeitrag
Conference Paper
2023 Product-specific Identifiers and Data Aggregation for Enabling Traceability in Battery Cell Production
Kies, Alexander D.; Siegert, Ferdinand; Ackermann, Thomas; Krauß, Jonathan; Grunert, Dennis; Schmitt, Robert H.
Zeitschriftenaufsatz
Journal Article
2022 Suitability of stainless steel and plastic belts for digital printing
Blasius, Laurin; Dormann, Sebastian; Zontar, Daniel; Brecher, Christian
Paper
2022 Enabling Sustainability in Glass Optics Manufacturing by Wafer Scale Molding
Strobl, Christian; Vogel, Paul-Alexander; Vu, Anh Tuan; Mende, Hendrik; Grunwald, Tim; Schmitt, Robert H.; Bergs, Thomas
Zeitschriftenaufsatz
Journal Article
2022 Green Growth - Wie Technologiemanagement einen Beitrag zur Nachhaltigkeitstransformation leisten kann
Schuh, Günther; Krebs, Leonie; Becker, Helen; Patzwald, Marc
Bericht
Report
Diese Liste ist ein Auszug aus der Publikationsplattform Fraunhofer-Publica

This list has been generated from the publication platform Fraunhofer-Publica