Amidst growing global demands for sustainable manufacturing, the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) proudly unveils FutureMold, a pioneering project to revolutionize the production of fiber-reinforced plastic (FRP) components. This innovative initiative, supported by leading European institutions and industries, is on a mission to drastically reduce environmental impact while cutting costs in mold manufacturing.
The FutureMold project addresses pressing challenges in the machinery industry today. Traditional methods for producing FRP components, such as hand lay-up, vacuum-assisted resin infusion (VARI), and resin transfer molding (RTM), are labor-intensive and wasteful, contributing significantly to both the carbon footprint and the cost of components, with up to 25% of production expenses attributed to mold manufacturing alone. “FutureMold seeks to disrupt this norm by introducing a hybrid approach that combines 3D-printed biopolymer molds with incrementally formed sheet metal surfaces, resulting in recyclable and more sustainable molds,” says Peter Scholz, coordinator of the FutureMold project.
FutureMold heralds a new era in mold manufacturing with its innovative hybrid mold concept, which reduces CO2 emissions and material waste by up to 95%. The molds are designed using a novel combination of 3D-printed fiber-reinforced biopolymers and metallic surfaces that can be fully detached and recycled after use. This approach not only extends the lifespan of molds by up to 300% but also cuts material costs by 80% and eliminates the need for disposable materials.
The project’s applications extend across multiple industries, including rail, marine, aerospace, and agricultural machinery, offering a sustainable solution for manufacturing lightweight, high-performance FRP components. The FutureMold project will develop prototypes that will undergo rigorous testing in industrial environments, ensuring readiness for market adoption.
As industries worldwide strive to meet stricter environmental standards, FutureMold stands at the forefront of this transformation. The project’s innovative approach contributes to significant reductions in energy consumption, material waste, and production costs, setting a new standard for sustainable production practices.
FutureMold is the result of an unparalleled collaboration between top research institutions and industry representatives from Germany, Poland, and Czechia, backed by the EU’s M-ERA.NET initiative. This partnership brings together expertise in areas such as polymer and metal additive manufacturing, digital workflow automation, and biocomposite development to drive forward innovation in sustainable manufacturing.
For more information about the FutureMold project, please visit the www.futuremold.eu website.
About Fraunhofer IWU
Fraunhofer IWU is a leading research institution in Germany, specializing in the development of efficient production processes. Focusing on sustainability and innovation, it is committed to driving technological advancements that benefit industry and society.
September 3, 2024, For Immediate release
Contact: Peter Scholz
Project Coordinator, FutureMold
Fraunhofer Institute for Machine Tools and Forming Technology (IWU)
Email: peter.scholz@iwu.fraunhofer.de
Phone: +49 371/5397-1253
Website: iwu.fraunhofer.de
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