Critical infrastructure such as transport networks are the lifelines of modern society. Extreme weather events may cause damage to railway tracks, roads, tunnels and bridges.

How can mass production methods be applied to individualized products? One answer is to use a combination of digital manufacturing technologies, for example by integrating digital printing and laser processing into traditional manufacturing processes. This paves the way for in-line product customization. Six Fraunhofer institutes have pooled their expertise to take the new process to the next level.

Thorough testing is paramount to the safety and reliability of the batteries that power electric vehicles. However, the lab tests conducted to date have been anything but realistic. Fraunhofer researchers have developed a new type of testing environment that combines physical components with mathematical simulations of vehicles. This setup is the first to enable lab trials under real-world conditions.

Plastic in cars reduces their weight. Currently, however, camshaft modules, which are a key component of powertrains, are still being made from aluminum. Now a research team from the Fraunhofer Institute for Chemical Technology ICT, in collaboration with their partners, has succeeded in manufacturing a camshaft module from fiber-reinforced thermoset polymers. This lightweight design element helps lower engine weight and reduces assembly costs. It is currently available as a functional demonstrator.

Lightweight technology has long been and is sure to remain a mainstay of automotive and aerospace engineering, shipbuilding and a host of other industries. Lighter materials and components could also help cut emissions that drive climate change. But lighter options are pricier, and the relatively steep cost has impeded their adoption. That is about to change thanks to the efforts of a consortium of automakers, suppliers and research institutes. Called ALLIANCE and coordinated by Daimler and the Fraunhofer Institute for Structural Durability and System Reliability LBF, this project has some good news for designers: As it turns out, it is entirely possible to build components that are up to 33 percent lighter at an added cost of less than three euros per kilogram-saved.

At the Fraunhofer Institute for Machine Tools and Forming Technology IWU, researchers are developing advanced technology for manufacturing fuel cell engines with the aim of facilitating their fast and cost-effective serial production.

Modern cars already feature a range of sophisticated systems such as remote-controlled parking, automatic lane-departure warning and drowsiness recognition. In the future, self-driving cars will also have auditory capabilities. Researchers at the Fraunhofer Institute for Digital Media Technology IDMT in Oldenburg, Germany, have now developed a prototype system capable of recognizing external noises such as sirens.

When it comes to cars that drive themselves, most people are still hesitant. There are similar reservations with respect to onboard sensors gathering data on a driver’s current state of health. As part of the SECREDAS project, a research consortium including the Fraunhofer Institute for Experimental Software Engineering IESE is investigating the safety, security and privacy of these systems. The aim is to boost confidence in such technology.

The amount of energy produced by renewable sources ebbs and flows. The Fraunhofer Institute for Industrial Mathematics ITWM has found a smart work-around for these fluctuations. Its scientists developed an innovative energy management system that connects photovoltaic systems, batteries, heat pumps and electric cars to power individual households or entire neighborhoods with locally produced renewable energy.