RAFINESS: Bio-based high-performance material

The materials used in aircraft construction must meet high requirements. In the "RAFINESS" project, Fraunhofer UMSICHT has developed a bio-based material that is specially designed for use in aircraft construction. It is characterized by good impact strength, flame resistance, and high temperature stability. The overall goal of the project was to print the novel material in and on a lightweight honeycomb panel using robot-guided additive manufacturing (RAM). Additive manufacturing ensures that the material is applied precisely where it is needed. This enables efficient use of the material and functional integrations that contribute to reducing the quantity and variety of materials used.

The bio-based material offers opportunities for a more sustainable aviation industry: the targeted use of materials in additive manufacturing can reduce the overall weight of an aircraft. This in turn leads to lower fuel consumption and thus a reduction in the climate impact of each individual flight. In addition, the use of fossil resources in interior materials is avoided. The planned reduction in the number of material types used through functional integration contributes to improved recyclability. In combination with other measures such as bio-based fuels, "RAFINESS" can support the industry's sustainability goals.

The glass fiber-reinforced material based on bio-based polyamide has been successfully developed. By combining stabilizers and processing aids, the researchers have succeeded in creating a technical material that is ideally suited for processing using RAM. The high thermal stability of the material prevents discoloration due to decomposition and smoke development during this demanding processing method. Its very low shrinkage enables precise printing without subsequent detachment from the substrate. Post-processing of the surface by milling is also possible without any problems.

Properties of the developed glass fiber reinforced plastic (GRP) based on bio-based polyamide

However, the material developed as part of "RAFINESS" is not only of interest to the aviation industry. Thanks to its flow properties and good demoldability with low shrinkage, it is also suitable for injection molding. This opens up a wide range of possible applications, for example in plant engineering or in the manufacture of electronic components.

• ZAL Zentrum für Angewandte Luftfahrtforschung GmbH
• Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
• SFS Intec GmbH

In cooperation with the Austrian project PIONEER

• FACC Operations GmbH
• Carbon Cleanup GmbH
• Transfercenter für Kunststofftechnik GmbH
• Kompetenzzentrum Holz GmbH