Our Motivation

Efficient lightweight structures can only be achieved through the right interaction of materials, design and manufacturing processes. The challenge here is not only the design of individual components in line with the materials and manufacturing processes, but also the lightweight design concept pursued across the entire system. Significant increases in efficiency in terms of structural weight and sustainability are possible, especially through the clever integration of a wide variety of functions into an overall structural concept and the development of multifunctional structures (functional lightweight design or system lightweight design).

With this in mind, we at the Institute of Lightweight Structures are developing various ideas and concepts to meet this approach. This includes both the further development or the use of novel material concepts as well as applications from the aerospace sector.

Functionalization by means of interphases

Multifunctionality by combining different polymer classes: This can be achieved by using interphases. These interphases form in the crosslinking reaction of thermosets in close proximity to thermoplastics. This allows thermoplastic properties such as weldability, impact resistance, insulation or chemical resistance to be applied to thermoset base materials to achieve a higher degree of functional integration.

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Development of a new generation of helicopter doors

In the LIGHT project, a new generation of helicopter doors is being developed using function-integrative and innovative manufacturing and design methods, including the validation of critical elements. The focus is on a shell design that can be produced in an automated and resource-saving manner and the application of electronic elements to expand the functional scope as well as weight reduction by substituting previously mechanical elements.

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Optimization of load application in sandwich structures

The BLANCA research project aims to realize load introduction in sandwich structures by bonding additively manufactured load introduction elements. By optimizing the sandwich structures used in conjunction with the use of optimally designed, bonded load introduction elements, the aim is to achieve an immediate weight saving compared to conventional structures and thus a lighter, more eco-efficient design.

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Structural Health and Event Monitoring of Space Structures

Within the SeRANIS project (Seamless Radio Access Networks for Internet of Space) we are dedicated to the development and integration of a vibration-based monitoring system for the detection of singular events (e.g. impacts of micrometeorites and space debris). This enables the basis and further research for the assessment of the structural health of space structures such as the research satellite "Athene-1" in low-Earth orbit.

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Active Mechanical Metamaterials

Mechanical metamaterials are complex 3D-printed lattice structures. These lattice structures are designed to achieve certain material properties, e.g. negative thermal expansion. Functional structures can be made from these materials, especially in combination with a control system. Within the SeRANIS project, we are developing functional structures for high-precision instruments on satellites and a corresponding in-orbit demonstration experiment.

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Multi-scale simulation of bonded fiber composites

Structural bonding offers considerable advantages as a joining method for fiber composites, but its safe and reproducible application in aerospace is still the subject of current research. An important aspect here is the reliable prediction of crack growth and damage behavior of bonded fiber composites. This is a necessary condition for the intended approval process of bonded joints under the concept of damage tolerance in aviation.

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Increasing the material utilization of fiber-reinforced composites with the aid of the 3D digital twin

The aim of the RICA research project is to reduce the scatter of material parameters in composites. The modification of standard test procedures, the consideration of additional parameters through the consistent use of 3D digital image correlation and the use of the digital twin should lead to higher design-relevant characteristic values. This leads to a positive effect in the dimensioning of lightweight structures, such as the reduced use of resources and also the use of fuels as well as reduced emission of greenhouse gases.

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Contact

Univ.-Prof. Dr.-Ing. Philipp Höfer

Univ.-Prof. Dr.-Ing. Philipp Höfer

Head of Institute
Gebäude 37, Zimmer 1105
+49 89 6004-5600
philipp.hoefer@unibw.de