Reference projects

The wood constituent lignin accrues in large quantities as a by-product of pulp and paper production. In collaboration with industrial partners, we are developing a high-performance bio-foam from lignin. In order to demonstrate its market potential, the lignin foam is being processed into molded parts for the automotive industry within the scope of the project. These parts are to be utilized as the core in car bumpers. Petrochemical foam materials could also be replaced by climate-friendly lignin foams in numerous other applications - for example in packaging, insulation materials or as a core material in wind-turbine rotor blades.

Protecting moorlands, avoiding greenhouse-gas emissions and, at the same time, extracting valuable raw materials for house construction and horticulture: That is the aim of this model and demonstration project, which is being implemented in two model regions in the districts of Emsland and Cuxhaven by a total of 13 partners from research and industry. The task of the Fraunhofer WKI is to thereby develop, manufacture and test construction products on the basis of cattails in close collaboration with the Fraunhofer IBP.

Small city apartments, house moves, and changes in living and working circumstances: These days, furniture has to fulfill demanding requirements in terms of functionality and flexibility. In collaboration with research partners and companies, we develop furniture that meets these requirements and is furthermore sustainable. The starting point is the new and further development of compounds, foams and imitation leather made from lignin - a plant-based residual material from industry. The aim is the creation of modular, lightweight furniture that can be easily disassembled, transported, repaired and repurposed. In other words, the service life of the material should be as long as possible. A further focus of the project is the recyclability of the furniture - from entire assemblies through to the single-type separation and preparation of the individual materials. Possibilities for the transfer of materials to other areas of application – such as the fashion industry and the motorhome sector – are also being considered.

Aerogels are highly porous, light-as-a-feather materials with extraordinary properties: extremely low thermal conductivity, low sound transmission, and a high adsorption effect on volatile organic compounds. They are excellently suited both for lightweight construction and as filter materials, and are therefore considered a material of the future. In collaboration with research and industrial partners, we are developing a process for the production of aerogels on the basis of waste wood. From the aerogels, we are creating prototypes of insulation materials and pollutant-adsorbing indoor-air filters that can be utilized in buildings and vehicles. Furthermore, transfer possibilities to applications in exhaust-gas cleaning are to be demonstrated. A further project objective: The raw materials required to manufacture the aerogels are to be recovered from the products. With this sustainable material solution, we are supporting health protection as well as the fight against climate change and resource scarcity.

Lightweight cars, trucks and trains made from renewable raw materials can contribute towards the protection of resources and the climate. As a joining technology for the production of lightweight components, adhesive bonding offers particular advantages and is therefore increasingly gaining in importance. In collaboration with research and industry partners, we are developing a bio-based, switchable PU adhesive for large surfaces. This should enable the production of panel-shaped laminated materials made from wood or wood and metal, which are not formed into 3D components until a later stage in the process chain. This opens up new possibilities for the flexible, economically efficient production of sustainable lightweight vehicles as well as for repair purposes and recycling. The special feature: Thanks to the re-detachable adhesive bond, it should be possible to separate the wood and metal according to type and with as little damage as possible.

Hybrid lightweight-construction materials made from renewable raw resources are increasingly gaining importance on the market. With such materials, resource- and climate-friendly products can be manufactured that fulfill several functions - for example, load-bearing construction products with integrated thermal and sound insulation as well as durable (upholstered) furniture and packaging. Efficient component geometries enable substantial weight savings with simultaneous high mechanical stability. In collaboration with research and industry partners, we are developing a process for the manufacture of complexly shaped products made from wood or agricultural materials and bioplastics by means of automated molding machines. One important component of the material and technology development is furthermore the highest possible material recyclability of the products after the end of the first period of use.

Buildings, bridges and towers made from wood bind CO₂ from the atmosphere and therefore contribute towards climate protection. For spruce – the classic source of construction timber – the growth conditions in Europe are becoming increasingly poor as a result of climate change. In addition, spruce wood has a limited durability. In collaboration with partners from industry and research, we are developing a sustainable and economical solution: a glued laminated timber made from robinia. This deciduous tree can cope better with the changing climate conditions than spruce and grows almost twice as fast. Robinia wood is as strong as oak and as resilient as tropical wood. Consequently, not only could robinia replace spruce and reduce the use of biocides, but the utilization of tropical wood and of finite resources such as steel and concrete could also be reduced through construction products made from robinia.

Resource conservation and energy efficiency determine the future of construction. Wood is an environmentally friendly and versatile building material. In addition to its ecological assessment, it also offers some technical advantages. Innovative timber-hybrid systems have even better mechanical properties, higher durability and allow for slender structures. Therefore, they are not only more resource efficient but also expand the architectural scope. In this project, we investigate and optimize the long-term behavior of wood hybrid systems, thereby laying the foundation for their use in the construction industry. Our main goal is to significantly increase the use of wood in building construction.

The lighter a vehicle is, the lower its energy consumption during the journey. Lightweight-construction solutions therefore play a significant role in the mobility of the future. In this joint project, lightweight semi-finished products and structural components are being developed for the vehicle industry. New design technologies should enable the integration of cooling structures as well as a production process that is both economical and saves materials. As a demonstrator, the battery system of an electric vehicle is being used. Our focus at the Fraunhofer WKI is directed at the development of a suitable fire-protection coating on the basis of renewable raw materials.

What will we use to make lightweight wood-based materials when there is no longer any spruce? In collaboration with the University of Göttingen, we are developing high-performance lightweight materials from hardwood for the construction industry. These could also be used in furniture, vehicles or transport packaging. Through our efforts, we are contributing towards the efficient utilization of semi-natural mixed forests. The wood-based materials industry can benefit from the sustainable raw-material security and new marketing opportunities.