IFW - Institut für Fertigungstechnik und Werkzeugmaschinen

🚀 Milestone in #CFRP Manufacturing: Topology-Optimised Fuselage Structure via #AFP Our colleagues from HPCFK have successfully produced a 1 x 1.5 m demonstrator of a topology-optimised CFRP fuselage section using Automated Fiber Placement (#AFP). This grid-stiffened structure, part of the #SHOREliner project, showcases the potential of AFP for lightweight #aerospace components – including the electric aircraft MDA1 eViator by MD Aircraft GmbH. In collaboration with the IFL - Institute of Aircraft Design & Lightweight Structures at Technische Universität Braunschweig, a process was developed that: 🔹 Integrates topology optimisation and AFP design rules 🔹 Enables automated geometry generation 🔹 Delivers results from design to component in under 5 weeks The component was presented at @Hannover Messe and is now on display at AERO Friedrichshafen. 🙏 Thanks to Deutsche Forschungsgemeinschaft (DFG) - German Research Foundation and Federal Ministry for Economic Affairs and Climate Action for supporting the projects OptiFee and SHOREliner. Further information via the link in the comments. If you are interested in the project, please feel free to 📩 contact Tim Tiemann directly via message.

🚀 Setting New Standards in #Manufacturing: Efficiency, Durability & Sustainability – Without Oxygen At the Fakultät für Maschinenbau der Leibniz Universität Hannover, eight institutes are jointly researching the future of oxygen-free manufacturing. Together, we're paving the way for next-generation production processes. As part of the Collaborative Research Center #SFB1368, the #IFW team is exploring oxygen-free environments in manufacturing – and the results speak for themselves: ✅ Up to 2x higher compressive residual stresses ✅ Up to 30% more axial residual stress ✅ Increased resistance to fatigue and cracking ✅ A step toward sustainable, high-performance production Industries like #Aerospace and #MedicalTechnology – where quality, reliability, and longevity are critical – stand to benefit immensely. We're now working on scaling these processes and exploring their full industrial potential. 👉 Interested in learning more or collaborating? Reach out to Sheng Laura Y. directly via message.

Tolerance allocation significantly impacts product functionality, quality, and costs. However, separate development and manufacturing processes often lead to inefficiencies and high costs. In the project 'Method for Knowledge-Based Tolerance Allocation and Function-Oriented Process Design', we collaborate with Technische Universität Darmstadt to develop a partially automated approach for #ToleranceAllocation and #ProcessPlanning. We are creating ontology-based assistance systems to integrate development and #manufacturing, enabling early specification of manufacturing parameters and precise tolerance allocation. Our research focuses on 3-axis #milling processes, using experimental studies to develop predictive models for form errors and methods for tolerance analysis and manufacturing effort estimation. The project aims to establish heuristic rules for tolerance allocation, forming the foundation for an assistance system that supports efficient, knowledge-based decision-making from the start. 🔹 Interested in applying these insights to your projects? Contact Andrii Skryhunets directly via message. 🔹 More information on our website. Link in the comments.

Our institute has a long-standing partnership with the Korea Institute of Machinery & Materials (KIMM). 🤝 A delegation from KIMM has now visited us in Hannover. Dr. Seog-Hyeon Ryu, President of KIMM, was welcomed by Prof. Dr.-Ing. Berend Denkena to discuss current research topics. This partnership has already led to several joint #research projects, and our collaboration is ongoing. For example, we are currently working together on the development of sensory guide carriages to advance the monitoring of machine tools. 🛠️ The goal is to create a solution suitable for mass #production. Together, we have reached a technology readiness level that allows for a demonstration at an in-house exhibition hosted by a leading Korean industrial partner, where the guide carriages are currently being showcased in South Korea. This week, representatives from both sides met at the IFW to share their experiences. 💡 The visit lasted several hours and covered various topics such as sensory components, digital twins, and potential new research fields. One thing is clear: there is strong potential for further joint research projects. KIMM is currently working on the future of production technology under its 'K-Machine' initiative. The IFW also aims to contribute to shaping this future through its research and can draw on a broad foundation of expertise. Our institute is therefore looking forward to continuing this successful #collaboration. For further information, please contact Eike Wnendt or Dennis Kowalke. 📩

Yesterday, the Industry working group #Tools held its members' meeting. In this group, we look at the entire manufacturing chain of cutting tools and face current challenges together with our partners from the industry. The current focus is on #EnergyEfficiency, conserving resources, increasing performance and simulation in the manufacture and use of cutting tools. The direct exchange with our industrial partners enables us to combine academic research with practical issues and jointly develop innovative solutions. Would you like to get actively involved or become part of the working group? Please contact Michael Zenger directly via message. Many thanks for your participation, BDW-BINKA Diamantwerkzeug GmbH, CemeCon AG, Haas Schleifmaschinen GmbH, MAPAL Dr. Kress KG, Neumüller, oelheld GmbH, Saint-Gobain, VOLLMER WERKE Maschinenfabrik GmbH, Walter Tools and ISCAR Germany GmbH. 🙌

Hannover Messe 2025: AI offers and aircraft lightweight construction Our colleagues from Mittelstand-Digital Zentrum Hannover are presenting a wide range of digital solutions and 🤖 #AI applications at the #HannoverMesse. From 31 March to 4 April, visitors will have the opportunity to try out innovative technologies live and talk to the experts from Mittelstand-Digital. Also on site: our colleagues from HPCFK with the ✈️ #SHOREliner – a fully electric CS-23 regional aircraft with ten seats. Developed as part of Germany’s LuFo VI-3 research program, it features composite lightweight construction and an innovative battery replacement system. 💬 Don’t miss the chance to explore the latest innovations and connect with our experts. Visit us at Hannover Messe 2025! More 🔍 information, free ticket link and how to get the AI readiness check on our website. Link in the comments.

🔬 Enhancing H13 Tool Steel with #AdditiveManufacturing & Mechanical Post-Processing The laser-based powder bed fusion (#PBF-LB) of AISI H13 tool steel enables innovative tool designs, such as internal cooling channels for die-casting and injection moulding tools, significantly extending their service life. However, the inherent limitations of additive manufacturing – such as high surface roughness and insufficient dimensional accuracy – necessitate mechanical post-processing, including milling and deep rolling. 💡 Our Research Approach Together with the Institut für Werkstofftechnik IfW (Universität Kassel) we investigate the combined manufacturing of H13 #ToolSteel, optimising surface and subsurface properties to enhance tool performance. By characterising and refining the process parameters of PBF-LB, milling, and #DeepRolling, we aim to: ✔ Improve hardness, microstructure, residual stress state, and roughness ✔ Extend service life and durability of H13 steel tools ✔ Develop an optimised process chain that integrates additive and conventional manufacturing techniques Are you interested in additive manufacturing and mechanical post-processing? Feel free to reach out to Philipp Pillkahn. Further information and contact details can be found on our website. Link in the comments.

This year's #SmartGreenIsland #Makeathon2025 took place in Las Palmas de Gran Canaria from March 12 to 15. The aim of the event was to get young people excited about technology and develop solutions to improve environmental protection and resource efficiency. The Makeathon was organized by ITQ GmbH for the 8th time this year. In total, over 500 young people from different countries and study programs took part in the event. The participants had four days to work on the “Industry Challenges” - tasks set by companies. These tasks included the development of autonomous vehicles for detecting and collecting waste or the development of a process chain for producing drinking cups from banana peels. All tasks were aimed at improving sustainability and environmental protection. Among the participants were eight students and research assistants from our institute, the IMPT Institute of Micro Production Technology and the match - Institut für Montagetechnik und Industrierobotik in order to gain experience for a possible Makeathon at Leibniz Universität Hannover. More information can be found on our website. Link in the comments.

Congratulations! 🎉 We congratulate Tobias Stiehl on his successful doctorate at the #IFW. In his #dissertation, Mr. Stiehl investigated the topic ‘Transfer of Knowledge between Machine Tools for Process Monitoring’. Thank you for the great work 🙌 and all the best for your personal and professional future!

Last week, the second Doctoral Retreat of the collaborative research project #HyPoTRR375 took place in Hannover. The event brought together #PhD students from various sub-projects and facilitated intensive 🔬🤝 interdisciplinary exchange. A key element of the event was the poster session, where students presented the current status of their research projects. The subsequent discussions fostered interdisciplinary exchange and created new scientific connections. The programme was complemented by two soft skills workshops focusing on 🎯 leadership and 🗣️ rhetoric. Particularly exciting were the lab tours at the various institutes of the 🔧 Hannover Centre for Production Technology. Participants gained practical insights into state-of-the-art research facilities. Among other things, the IFW team presented sub-project A05, which focuses on simulating the additive manufacturing of hybrid porous components. The project aims to predict and optimise the material properties of these innovative structures through 🖥️ process simulations. The #DoctoralRetreat provides a valuable opportunity for scientific exchange and personal development. Equipped with new 📚 knowledge and fresh 💡 ideas, the PhD students are now continuing their #research with renewed 🚀 motivation. For further information please contact Mariem Ben Salem via message.