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Lightweight construction is considered a key technology of the future. It provides an important contribution towards increasing competitiveness and achieving climate and sustainability goals. Lightweight materials, components and products require less transportation energy and often also smaller amounts of raw resources. Lightweight products made from renewable raw materials can be particularly sustainable. Even renewable raw materials will, however, become scarce if they are used to create an ever-increasing number of products and the world’s population continues to grow. Researchers at the Fraunhofer WKI are developing resource-efficient lightweight-construction solutions using renewable raw materials: from the development of alternative raw materials from climate-adapted ecosystems and plant residues, through material and process development, component design and quality control, and on to cascade utilization and recycling.

In collaboration with industrial partners, researchers at the Fraunhofer WKI have developed a vehicle underbody made from natural fibers and recycled plastics for automotive construction. The component fulfills the stringent technical requirements in the underbody area and could replace conventional lightweight vehicle underbodies in the future. With this development, the climate and environmental balance is optimized throughout the entire product life cycle. The focus at the Fraunhofer WKI was directed at the development of the materials for injection molding as well as the hydrophobization of flax and hemp fibers for natural-fiber-reinforced mixed-fiber non-wovens.

Two research highlights from the Fraunhofer WKI will be on display at the Hannover Messe from the 22^nd to the 26^th of April 2024 in the “Schaufenster Bioökonomie” (Bioeconomy Showcase): thermal-insulation bricks filled with beech-wood fibers and a formaldehyde-free bio-adhesive for the production of wood-based materials. The “Bioeconomy Showcase” is a joint stand operated by Project Management Jülich (PtJ) and the Fachagentur Nachwachsende Rohstoffe e. V. (FNR). Research results from current bio-economy projects funded by the German Federal Ministry of Food and Agriculture (BMEL) and the German Federal Ministry of Education and Research (BMBF) will be presented here.

The Fraunhofer WKI will be presenting solutions for lightweight construction using renewable raw materials at the Hannover Messe from the 22^nd to the 26^th of April 2024. A wood-fiber-based molded part demonstrates the potential of lightweight hybrid materials and was produced using an automated molding machine. The process offers possibilities for the precision-fit production of complexly shaped components, furniture or insulation materials. Furthermore, the performance capabilities of renewable raw materials will be demonstrated with a ceiling system module on the basis of wood foam. The module can be utilized for the renovation of suspended ceilings in old buildings. The mosaic-like coffered ceilings exhibit a load-bearing capacity comparable to reinforced concrete, but are significantly lighter. The innovations can be seen on the Fraunhofer stand (Hall 2, Stand B24).

From raw materials to recycling - at the Hannover Messe from the 22^nd to the 26^th of April 2024, the Fraunhofer WKI will be presenting new application possibilities for renewable raw materials at the Fraunhofer joint stand (Hall 2, Stand B24). The examples range from a wooden crash barrier for road traffic through to sustainable concrete construction materials made from residual materials. They demonstrate the potential of renewable raw materials for the circular economy.

For the company Modvion AB in Gothenburg, researchers from the Fraunhofer WKI accompanied the bonding of the first wooden tower for commercial wind turbines on the construction site and advised the company on complex bonding processes. The so-called "Wind of Change Tower" of the energy provider Varberg Energi AB was inaugurated on 4 March 2024.

As of 1^st March 2024, Dr. Steven Eschig has taken over the management of the “Binders and Coatings” department at the Fraunhofer WKI. The chemist, who had already worked as a research associate at the Fraunhofer WKI, aims to further develop bio-based adhesives, coatings, flame retardants and other chemical products through interdisciplinary collaboration with industry and research partners. Dr. Steven Eschig succeeds Dr. Frauke Bunzel, who had been in charge of the department since December 2018.

Within an interdisciplinary project in collaboration with partners, researchers from the Fraunhofer WKI have investigated the quality of softwood from differing silvicultural systems. The aim of the project was to improve the supply situation for the construction industry in view of climate change. From the results, recommendations for new plantations can be derived in order to specifically optimize wood quality and wood yield. Researchers at the Fraunhofer WKI addressed the visual sorting of softwood and determined that application-oriented sorting based on product requirements – and, consequently, more efficient use of wood resources – is possible in dependence on silvicultural parameters. A re-evaluation of various visual criteria can be advantageous.

When it comes to sustainable development, the construction industry faces great challenges. In the ReMatBuilt project, experts from the Fraunhofer WKI and their partners are proving that the tasks associated with this can be solved with high-performance construction materials made of recycled and waste materials. They will be presenting their solutions to specialist audiences at the Hannover Messe Preview on February 21, 2024.

On 8 February 2024, the kick-off event for the new mentoring programme of the Fraunhofer WKI took place in Bratislava at the Slovak Centre of Scientific and Technical Information. The aim of the "Upgrade of the Centre of Excellence LignoSilva" project, which is funded by the European Union, is to strengthen scientific excellence and international research contacts. The Fraunhofer WKI will act as a mentor in the coming years.

Researchers at the Fraunhofer WKI, in collaboration with the company IGP Chemie GmbH, have further developed a non-combustible filling and installation foam in such a way that it complies with construction-material class A1 and possesses low thermal conductivity. As a result, the installation of fire-resistant doors and windows and the sealing of openings in fire-resistant walls is simplified. In addition, the Fraunhofer WKI, in collaboration with project partner GWK Kuhlmann GmbH, has utilized the new foam in the production of prototypes for prefabricated insulation shells for fittings and valves - an innovation for fire protection in construction that will be further developed for industrial applications in a follow-up project.

In a joint research and development project between Germany and Brazil, the cooperation partners want to improve the carbon footprint of construction products. To achieve this, they will use, for example, natural bamboo fibers for cement-based composite materials. The overarching aim of the international project is the promotion of market-oriented research and experimental development projects in Brazil. The first interim results have now been exchanged during a workshop in Brazil.

On the 27^th of October 2023, the Minister of Agriculture, Cem Özdemir, presented the participating project partners with the funding notification from the German Federal Ministry of Food and Agriculture (BMEL) for the research project “Nachhaltige Erzeugung und Verwertung von Rohrkolben auf Niedermoorstandorten in Niedersachsen“ (Sustainable production and utilization of cattails on fenland sites in Lower Saxony, “RoNNi”).

In collaboration with Schwan Cosmetics International and Worlée-Chemie, the Fraunhofer WKI has developed high-quality bio-based film-formers on the basis of lignin for use in cosmetic products. The foundation has therefore been laid for high-quality and sustainable makeup products whose quality is in no way inferior to that of conventional products.

The wood foam developed and patented by the Fraunhofer WKI will, in future, be produced and distributed by Butterweck Holzstoffe GmbH & Co. KG. The marketing of the wood foams is planned under the brand name LIGNEW. Construction work for a production plant in Northern Germany will commence shortly. Delivery of the first wood-foam panels is expected to take place in 2026. The researchers at the Fraunhofer WKI will continue to provide Butterweck Holzstoffe GmbH & Co. KG with support in an advisory capacity.

On September 29, 2023, the University of Primorska and its partners celebrated an important milestone: the successful completion of the project phase of the largest European research and innovation project in Slovenia. Representatives of the European Commission attended the event, where the main project results and future plans of the InnoRenew Center of Excellence (CoE) were presented. The Fraunhofer WKI had accompanied the founding phase of the center as a mentor.

Fraunhofer researchers are highlighting the scientific and technological potential of the bioeconomy in their roadmap “Circular bioeconomy for Germany”. Included are recommended actions to be taken at a political level. The roadmap was presented in Brussels on September 20, 2023. The Fraunhofer WKI contributed to the roadmap.

The Fraunhofer WKI, in collaboration with the University of Stuttgart, the Laser Zentrum Hannover and industrial partners, has produced a column made from natural-fiber-reinforced bioplastic by means of 3D printing. The column is currently on display at the Biennale in Venice. With the column, the researchers are demonstrating that 3D-printed materials are also suitable for large components in architecture.

In collaboration with the companies Leichtwerk AG and Jowat SE, the Fraunhofer WKI has developed a sustainable multicopter. Thanks to an efficient, bio-based structural design and modular construction, the new aerial vehicle is significantly more sustainable than comparable conventional systems. In order to achieve this, the Fraunhofer WKI has developed functional materials, manufacturing processes for molded parts, and suitable coatings.

Switchable adhesives are suitable for the adhesion of cement-bonded wood-based panels. This has been verified by researchers at the Fraunhofer WKI in collaboration with industrial partners. With the aid of – amongst other things – block shear tests, the project team showed that the minimum requirements are fulfilled through the use of the newly developed adhesives.

On 1st July 2023, the researchers from the Fraunhofer WKI Application Center HOFZET^® will be able to look back upon 10 years of research activities in the fields of sustainability, materials development and component development as well as circular economy and recycling.

Researchers at the Fraunhofer WKI, in collaboration with their partner Protohaus gGmbH, have constructed a stage set for the Braunschweig State Theater using an innovative forward-looking material. The surface of the mountain landscape in the play “Funken” was created with the help of fungal mycelium. The ecological and recyclable building material consists of elephant-grass fibers, which are grown through with mycelium. The stage set creatively illustrates the potential of building with fungal mycelium for the general public. The lampshades that can be seen on stage have also been produced using mycelium that has been hot-pressed in an innovative process.

During LIGNA 2023, researchers from the Fraunhofer WKI will be presenting possibilities for utilizing renewable raw materials – such as balsa wood, hardwood or natural fibers – in future-oriented applications. The application possibilities will be demonstrated by means of a laminated-material bridge and an eco stand-up paddleboard.

By means of a wood-based panel for interior construction, researchers from the Fraunhofer WKI will be demonstrating the application possibilities for a newly developed, formaldehyde-free bio-adhesive at LIGNA 2023. Compared to the phenol-formaldehyde resins often used until now, the new lignin-HMF resin is harmless to health and free from petrochemical raw materials. The researchers are presenting a 100 percent bio-based condensation resin for the wood-based materials industry that can be manufactured and processed using conventional process and equipment technology.

By means of a wall made from a multi-layer composite material as well as a ceiling beam, researchers from the Fraunhofer WKI will be demonstrating utilization possibilities for pine wood at LIGNA 2023. The demonstrators are the result of two current research projects at the Fraunhofer WKI. The “wood of the future” pine is one of the most important tree species in Northern Germany in terms of area covered and copes relatively well with climate change. As pine wood will be available in greater quantities in the future, the researchers are working on the development of application fields with high revenue potential for the construction and automotive industries.

In a current research project, researchers at the Fraunhofer WKI are determining how beech wood, which will be increasingly available in the future, can be used as wood-fiber insulation material in the form of mats or foams. At LIGNA 2023, the researchers will present one possibility: a thermal-insulation wall made from hollow bricks filled with insulation mats composed of beech-wood fibers. The brick wall is part of the “Multi-material model Wall I Ceiling I Roof”. Industrial partners will test the insulating materials developed at the Fraunhofer WKI to ensure their practical suitability. The project team is working on an economically attractive solution for the production of wood-fiber insulation materials from beech wood for the construction industry.

With the ceiling-system module for the modernization of suspended ceilings in buildings, researchers at the Fraunhofer WKI are demonstrating at LIGNA 2023 an ecological possibility for the renovation of old buildings. With the prefabricated small panels in modular construction, renovations will be easier and faster to carry out in the future.