High-profile research projects, closely integrated with industry, form a cornerstone of the planned Wolfsburg Campus. In the research element, the fields of action for the circular economy in mobility are defined through interdisciplinary research groups known as "Joint Research Groups" (JRGs). These groups address topics such as "Automated Complete Vehicle Disassembly," "Sustainable Material and Surface Systems," "Adaptive Processing of Bio-Based Materials," and "AI-Based Product Development and Optimization."
With fossil resources depleting and their environmental impact increasing, transitioning to bio-based and sustainable materials has become a global priority. The development of innovative materials from renewable raw materials offers the potential to leverage nature’s biodiversity for sustainable applications. Plants are among the most important biomass producers. A key aspect is that no raw materials required for food production are used in the manufacturing of bio-based materials. The integration of bio-based waste and fuels into a sustainable material cycle represents an attractive solution. However, numerous challenges must be overcome to successfully recycle these biomasses and integrate them into circular material concepts that meet mechanical requirements. This innovation step would significantly enhance the application potential of bio-based materials in major industries such as mobility. Additionally, wood, as a sustainable bio-based material, offers enormous application potential both in its natural form and as a modified material, thanks to its excellent mechanical properties, positive CO2 balance, high availability, and relatively low cost.
The goal of the Joint Research Group "Adaptive Processing of Bio-Based Materials" is to develop scalable manufacturing processes for the production of high-performance components from renewable materials. The JRG involves cross-institutional collaboration with partners from TU Braunschweig (Institute for Joining and Welding Technology, Institute for Machine Tools and Production Technology, Institute for Mechanics and Adaptronics), Ostfalia University (Institute for Recycling), and the Fraunhofer Society (Institute for Machine Tools and Forming Technology). Intensive networking with the three other JRGs facilitates the exchange and synergistic use of research findings. JRG “Adaptive Processing of Bio-Based Materials” specifically addresses the varying properties of natural raw materials. The entire production chain is mapped to develop suitable production and tooling concepts. Bio-based plastic systems that do not compete with food production are analyzed, and their recyclability for a functioning circular economy is evaluated. Additionally, recycling-oriented functional integrations and appropriate condition monitoring procedures are implemented. The developed concepts undergo comprehensive evaluation, focusing on the scalability of results.
The project aims to resolve the conflict between bio-based materials and consistent product quality. The processing approach considers the principles of the circular economy and recycling-oriented functional integration right from the raw material stage. The work packages include identifying suitable functional composites for the transition from cladding parts to structural components, inline material characterization for the creation of adaptable material maps using AI methods, and the development of adaptive processing techniques to ensure high product properties. Furthermore, functional demonstrators will be created, and recycling concepts will be tested.
Additionally, the goal is to develop integrative processes for resource-efficient and renewable raw materials using forming and machining processes. To achieve this, requirements will be analyzed, with a focus on ergonomics and safety, as well as the hybridization of bio-based components to integrate structural and non-structural functions. Work processes will be automated and optimized for scalable production.
