Chris Liebold
The climate crisis is one of the greatest challenges of our time and requires comprehensive measures to achieve the EU's goal of climate neutrality by 2050. The manufacturing industry, which accounts for 22.7 % of gross value added in Thuringia, above the national average, plays a key role in this. This applies in particular to the ‘manufacture of rubber and plastic goods’ sector, as plastics are indispensable, but their production is resource-intensive and contributes significantly to global greenhouse gas emissions. A key approach to decarbonising the manufacturing industry is to increase energy and resource efficiency in production and thus reduce CO₂ emissions in all phases of the life cycle of technical products. This includes the development of sustainable production strategies to reduce energy consumption, emissions and the use of raw materials as well as material substitution through the use of biogenic composite materials made from renewable raw materials, which consume less energy and resources and bind CO₂.
Felix RöhnertComposite materials such as fibre-reinforced plastics are increasingly gaining market share, particularly in the field of lightweight construction. In addition to technical fibres (glass, carbon, aramid), natural fibres from biogenic sources such as flax, hemp, jute or wood are also playing an increasingly important role. The focus of the project is on highly filled composite materials with natural fibres and a polymer matrix (biogenic plastics). In order to create practical applications for small and medium-sized (SME) plastics processing companies in Thuringia, the project is focussing on commercially available materials.
The combination of recyclability, mouldability and carbon-binding natural fibres enables a considerable reduction in environmental impact, particularly through reduced raw material usage and less production waste. However, natural fibres and the necessary additives influence the material properties as well as the behaviour during processing and in later phases of the product life cycle. Adequate scientific foundations are still lacking here. In order to take into account the special features of biogenic plastics, adapted techniques for primary forming, separating and joining must therefore be developed (e.g. injection moulding processes, additive manufacturing).
The production and processing of biogenic plastics requires transparency regarding the use of energy and resources. Sustainable product design must be taken into account as early as the development stage, as companies are increasingly required to provide proof of sustainability (e.g. through digital product passports or supply chain laws).
The aims of the project are therefore:
In order to achieve the work objectives, the solution is orientated towards the production chain. Vehicle interior components serve as examples for the investigations. Biogenic compounds made of natural fibre and PP/PE matrix are being investigated. Alternatively, a bio-based material based on cellulose can be tested. The plastic parts are produced by injection moulding and by means of granulate-based extrusion in additive manufacturing. In the next step, an assembly consisting of the plastic part and a thin-walled metal sheet is created by bonding and screw connection. Image-based measuring methods optimise the manufacturing process. Resource consumption is analysed and adjusted for energy and material efficiency.
Dr. Andreas PatschgerThe project results will create a basis for Thuringian companies that will lead to expanded business models and competitive advantages through targeted transfer. The project paves the way for Thuringian plastics processors to transform from a traditional supplier in the sense of an ‘extended workbench’ to a quality supplier of components made from biogenic plastics with an extended service portfolio. The practice-orientated focus of the research group and the close networking with Thuringian companies also promote the development of new R&D projects during the project phase. In view of the high regional relevance of the topic, further projects with Thuringian participation are expected, both through state and federal funding and through self-financed commercial projects.
The expertise developed through the project can be pooled at the Thuringian Centre for Mechanical Engineering (ThZM) and further developed and transferred as a separate area of expertise. This will enable the ThZM to act as a contact and expertise partner for Thuringian companies in the field of resource-saving production and the associated balancing.
The research group is made up of scientists from the 5 ThZM research institutes*, young scientists and an industrial advisory board (Thuringian companies in the plastics industry and experts on the topic of CO₂ neutrality/sustainability).
*The Thuringian Centre for Mechanical Engineering (ThZM) is a project launched in 2013 by five research institutions in Thuringia: Ilmenau University of Technology, Schmalkalden University of Applied Sciences, Ernst Abbe University of Applied Sciences Jena, Gesellschaft für Fertigungstechnik und Entwicklung e. V. (GFE) and Günter-Köhler-Institut für Fügetechnik und Werkstoffprüfung GmbH (ifw).
CONTACT
Prof. Stephan Husung
Faculty of Mechanical Engineering
Head of the Department of Product and System Development and coordinator of the EMProBio research group
stephan.husung@tu-ilmenau.de
