This innovative development seeks to improve mechanical properties and thermal management while reducing weight for applications such as electric motor housings, power electronics housings, and battery cases.
MULTHEM focuses on researching and improving advanced components made of a variety of materials such as carbon fiber carbon composite (CFC), aluminum and copper. Particular emphasis is placed on increasing thermal conductivity through using innovative nanotechnology and synergetic material combinations.
MULTHEM aims to develop metal-polymer-based multi-materials for lightweight structures with good thermal management using additive manufacturing (AM) and innovative joining technologies to achieve complex freeform geometries. At present, metal structures are often replaced with carbon fibre composites (CFCs) to produce lightweight features with outstanding mechanical strength, to be used for example in aircraft or high-performance vehicles. Further weight reduction can be achieved by using Additive Manufacturing (AM) to create intricate geometries that cannot be manufactured using conventional methods, and by applying reinforcement only where it is needed.
MULTHEM focuses on researching and improving advanced components made of a variety of materials such as CFCs and aluminium alloys. Particular emphasis is placed on increasing thermal conductivity by using innovative nanotechnology and synergetic material combinations, applying innovative joining technologies.
Combining CFCs with aluminium alloys aims to improve thermal conductivity and mechanical properties. As a result, components with optimized structural and cooling properties, such as battery cases, electric motor housings and power electronics housings, can be produced cost-effectively. These cases and housings would be lighter and stronger than those made of aluminium or steel. This not only increases product performance by reducing weight, but also lowers operating costs, particularly in sectors such as aerospace and automotive engineering. Ultimately, the growth of the companies involved will be significantly boosted by MULTHEM's innovations.
The vision of the MULTHEM project benefits a range of industries and companies. These include SMEs as well as large companies in the composites industry, the additive manufacturing industry, battery manufacturers and power electronics. This not only promotes more environmentally friendly production, but strengthens the competitiveness of companies as well. Innovative material design allows them to diversify their product range and expand their market presence.
As part of the MULTHEM project, Fraunhofer IPK is responsible for the work package »Joining Technologies«. We are developing and investigating joining concepts for the production of multi-materials using innovative joining technologies such as laser and electron beam technologies. We also calculate the environmental impact of the newly developed multi-material products developed in MULTHEM and compare them with conventionally manufactured products using Life Cycle Assessment (LCA).
Our objective is to develop new methods for manufacturing multi-material joints for various applications and to understand the factors that influence these joints. This will enable MULTHEM to produce high-quality multi-material joints wherever needed, supported by the simulation of joining processes to better understand these influencing factors.
A major challenge in producing new metal-polymer multi-materials is achieving a strong bond between dissimilar materials due to their different physical and chemical properties. To overcome this challenge, Fraunhofer IPK has developed a novel method called “Electron and Laser Beam Bonding,” which uses advanced thermal joining technologies to create strong, reliable bonds between aluminium alloys and CFCs.
As part of the project, an international consortium of experts from research and industry was created. Together, we plan to research the theoretical foundations and practical applications of this promising process. Our approach is to promote cooperative research and development work in order to eventually create commercially viable products that offer both ecological and economic benefits.
Ultimately, we want to make an important and sustainable contribution with our project by driving forward the development of new technologies, increasing productivity, conserving resources and strengthening the competitiveness of our target audience. We encourage all interested stakeholders to join us on this innovative journey and become part of a game-changing movement at the intersection of materials science, nanotechnology and advanced manufacturing such as additive manufacturing and joining technologies..
A detailed description of all partners is available here.
Fraunhofer Institute for Production Systems and Design Technology