Competence field

Plastics Technology and Lightweight Design

Univ.-Prof. Dr.-Ing. Dipl.-Wirt.Ing. Florian Puch

Director of the Plastics Technology Department

+49 3677 69-2841

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Competence Field Plasctics Technology and Lightweight Design

The competence field lightweight design aims to use plastics in automotive components and structures to reduce weight while improving mechanical and functional properties. The following technology fields, which are used in numerous areas of vehicles, are pursued:

  • series production process for fiber composite technology
  • multi-component process technology
  • hybrid component manufacturing technology, connection technology, and integration techniques for multifunctional assemblies and
  • intelligent plastic components with high functional integration


Reference Project

HeKoSch – Design and development of a head expander for a vibration test system consisting of a sandwich composite made of carbon fibers and plastic foam

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Reference Project

Project name:
HeKoSch – Design and development of a head expander for a vibration test system consisting of a sandwich composite made of carbon fibers and plastic foam

Project period:
01.07.2016 – 30.06.2018

Project consortium:
Coordinator: Schmuhl Faserverbundtechnik GmbH & Co. KG, Egertsweg 3, 07368 Remptendorf (medical lightweight components, components for commercial vehicle sector) TIRA GmbH, Eisfelder Str. 23-25, 96528 Schalkau (classical mechanical engineering, material testing technology, vibration testing technology, balancing technology) Technical University Ilmenau - Department of Plastics Engineering, Gustav-Kirchhoff Straße 5, 98693 Ilmenau

Substitution of conventional metallic construction materials by lightweight hybrid composites allows weightsaving design of moving components within machinery and equipment. As part of the research project HeKoSch, the basics for the use of a material combination of carbon fiber reinforced, thermosetting plastics and thermoplastic foams in hybrid sandwich construction are being developed for use in machine components under vibrational stresses.

The material behavior of such sandwich composites is investigated. Engineering expertise for the development and construction of complex structural components will be evolved and essential processing aspects will be analyzed. This concerns possibilities and abilities of the characterization and simulation of material properties, component design, integration of joining and force tansmission elements as well as consideration of significant manufacturing process parameters.

The findings and technologies arising out of this project allow use and further development of specialisation benefits and potentials to further promote sustainable growth. Important sectors of Thuringia such as mechanical engineering, automotive sector, energy technology as well as the end user benefit directly from the findings developed in the project due to the newly-created option of producing lightweight, structurally rigid and vibration-damping components and products.

The specialization field „Industrial Production and Systems“ will be further developed - the technological strength of the Thuringian mechanical engineering and toolmaking industry will be strengthened by applying the researched material combinations. By mastering the science of complex technical production processes the companies will be able to offer intelligent, efficient and competitive system solutions.

Electrodynamic vibration test system for frequency analysis in vertical direction for motos vehicles