Fraunhofer Institute for Production Technology IPTResearch project "MemForm3D"
MemForm3D: New Paths in Thin Glass Forming
Thin glass is a key material in high-tech applications – from LiDAR sensors and head-up display mirror substrates in the automotive sector to glass encapsulation for semiconduc-tor manufacturing. Glass offers scratch resistance, high transparency, and chemical du-rability. But when it comes to complex geometries or perforations, conventional manu-facturing methods reach their limits.
Combination of membrane technology and vacuum-assisted forming
In the research project “MemForm3D”, Fraunhofer IPT is developing and validating a novel molding process that overcomes these challenges. The technological innovation is based on a combination of non-isothermal process control and a specially developed tooling concept. The technology has been patented by Fraunhofer IPT.
The result: components with outstanding contour accuracy, minimal shape deviation, and extremely low surface roughness. Time-consuming post-processing steps such as polishing are no longer necessary thanks to the use of alternative tool materials instead of graphite. This reduces the overall manufacturing effort – a key advantage in terms of production efficiency and sustainability.
Patented technology makes glass processing more efficient, faster, and cost-effective
At the heart of “MemForm3D” is a new forming unit that shapes thin glass into the desired geometry using a flexible membrane and controlled overpressure. The air can be heated if needed, enabling stable process control. The specially developed tooling sys-tem includes the flexible membrane unit, a precise sealing system, a compressed air inlet, and an optimized preheating concept for the forming fluid. This technology en-sures uniform forming, avoids mechanical stress, and preserves the flawless surface of the glass.
Thanks to the non-isothermal process control, which uses targeted temperature gradi-ents, the forming process can be significantly accelerated. This not only reduces produc-tion times but also minimizes waste and tool wear – a major advantage for industrial-scale manufacturing.
The patented combination of membrane technology and vacuum-assisted forming makes glass processing faster and more resource-efficient than ever before. Especially compared to press bending, which primarily uses graphite tools and requires elaborate post-processing such as polishing, production costs are significantly reduced. At the same time, material efficiency increases – lowering the environmental impact.
Wide range of applications and future potential through digitalization
The technology developed in the project is not limited to thin glass. It can also be adapted to other types of glass and geometries. This opens up a wide range of applica-tions in optics, electronics, and the semiconductor industry. With its high process stability and scalability, MemForm3D is a forward-looking solution for the industrial production of high-precision glass components.
In addition, full process data acquisition enables the integration of artificial intelligence. Data-based optimization can further improve manufacturing processes and generate new insights for glass processing.
Funding
The “MemForm3D” research project is funded by the European Union and the state of North Rhine-Westphalia as part of the EFRE/JTF Programme NRW 2021–2027.
Funding reference: EFRE-20800481
Project sponsor
Project Management Jülich