Cost-efficient solutions for medium-sized businesses –

Additive manufacturing processes offer significant potential for lightweight and load-optimized components made of advanced materials. Together with INVENT GmbH, we analyzed the application possibilities of topology-optimized additively manufactured metal joint elements. Using the example of a real component for aerospace applications, we developed a new component design and qualified it for manufacturing using additive laser powder bed technology.

As a result, we fabricated a design-optimized, additively manufactured component with higher stiffness and lower weight. Under representative and application-oriented test conditions, we demonstrated with the developed optimizations the Technology Readiness Level (TRL) "near flight qualified". Despite the high technical demands, the research partners solved the task quickly and with high precision. Fraunhofer IWS's many years of experience and its modern equipment in the field of additive manufacturing, covering the entire process chain, contributed to this success.

More cost-efficient organic photovoltaics (OPV) with ultrashort light pulses – thanks to a precisely adapted laser process, our researchers have succeeded in cutting OPV stacked layers with micrometer precision for a medium-sized solar film producer. To this end, we have defined the appropriate process. A picosecond laser divides the photoactive as well as the supporting electrode material of the layer stacks according to the current path to enable the cell to be electrically interconnected.

The challenge: The integrated barrier layer must remain intact. Instead of glass, the barrier layer protects the solar cells from environmental influences. This selective process is the prerequisite for advancing the development of organic photovoltaics. In this way, it saves weight compared to crystalline solar cells and can generate energy both in mobile form and on freely formed surfaces.