Sustainable series production with fiber-reinforced plastics

Fiber-reinforced plastics (FRP) are ideal for lightweight construction and are being used more and more frequently in many fields of application, from mobility and transportation to construction and energy generation: wherever low component weight is important, they also score with their good corrosion resistance and electrical insulation.

For this reason, lightweight materials such as glass fiber reinforced plastics (GFRP) can be found, for example, in numerous components for wind turbine blades, sport boat hulls, antenna, lantern and overhead line masts or pipe systems. Carbon fiber reinforced plastics (CFRP) are widely used in vehicle construction, aerospace and sports equipment and other lightweight but highly durable consumer products.

Automation solutions for the cost-effective series production of FRP components

This increasing industrial use of a wide variety of FRPs is leading to growing demand for processing methods suitable for large-scale production. The use of unidirectional thermoplastic tapes and thermoset prepregs makes it possible to fully automate the manufacture of FRPs and transfer them to large-scale production. Fraunhofer IPT is developing systems and processes for automated tape and prepreg processing of such FRP materials, enabling companies to move into customized, efficient and cost-effective series production.

New approaches to data collection and utilization, as well as virtual process models, create the prerequisites for adaptable, large-series processing of glass- and carbon-fiber-reinforced thermoplastics and thermosets. Fraunhofer IPT automates the systems and processes for processing these materials, thus enabling efficient and flexible production of lightweight components for various industries.

Made easy: manufacturing processes for new products made of FRP materials

In many industrial sectors and for numerous consumer goods, lightweight construction serves to save energy and raw materials. Automated machining and processing methods make it possible to manufacture products from FRP in large quantities. Fraunhofer IPT is developing production-ready manufacturing processes that help to make the benefits of these materials accessible to a large number of people.

Unbreakable: Fiber-reinforced components in research

Tape laying and prepreg processing

Systems and processes for automated tape and prepreg processing enable companies to achieve customized, efficient and cost-effective series production.

Thermoforming of organic sheets

For structural components and free-form surfaces made of thermoplastic semi-finished products, we develop multifunctional thermoforming processes and associated system technology.


Winding process for tanks and pipes

Glass and carbon fiber-reinforced plastics are particularly suitable for lightweight, stable and corrosion-resistant pipes and pressure vessels, for example for oil and gas production or energy storage.

Micro pultrusion and pullwinding

For particularly small FRP components, we have miniaturized pultrusion and pullwinding processes to produce profiles with diameters below 500 microns.

Shear cutting of FRP

A cost-effective alternative to waterjet cutting, laser processes and machining of FRP components.

Handling technology for organic sheets

Automated handling technology and gripper technologies for dry, impregnated or cured fiber composite semi-finished products and technical textiles.

Integrated sensor technology for structure monitoring

Integrated sensor technology in FRP components can detect stress and wear at an early stage and prevent component failure.