Fraunhofer ITWM at the K 2025

Digital Solutions for the Plastics and Rubber Industry

Press Release / August 28, 2025

Under the motto »Lighter – More Durable – More Digital«, the Fraunhofer Institute for Industrial Mathematics ITWM presents its technologies and software solutions for the plastics and rubber industry at K 2025 in Düsseldorf from October 8 to 15, 2025. At the joint Fraunhofer booth (Hall 7, Level 0, Stand SC05), the researchers showcase their latest developments in digital material simulation, quality assurance and process optimization.

With FOAM, researchers at the Fraunhofer ITWM present software that simulates the expansion and mold filling of PU foams in any geometry. It is used for the digital design and optimization of components with foam filling – for example in cooling units, battery modules, car seats or sandwich panels. The aim is to ensure even foam distribution and optimum thermal and mechanical properties. The software uses a digital twin that virtually maps the entire development and production process. It takes into account complex requirements such as venting points, material requirements, nozzle movement and gas avoidance. The model parameters are automatically derived from real foaming tests. »Our simulations help to significantly reduce material usage and development time – a real added value for the industry,« explains Dr. Konrad Steiner, head of department »Flow and Material Simulation« at Fraunhofer ITWM.

Digital Design of the Lye Tank of a Washing Machine

Researchers will also be presenting the »DigiLaugBeh« project, in which they are using digital simulations to make a washing machine lye container more energy-efficient and resource-saving. The focus is on the development of a digital twin that can be used to virtually optimize materials and components. Instead of the short-fiber-reinforced thermoplastics used up to now, long-fiber-reinforced plastics are used, which offer higher stiffness and a better fatigue endurance.

The simulations take into account both macro and micro levels, including the injection molding process and environmental balance. The result is a robust, durable lye container that remains stable even at high spin speeds.

Terahertz Technology for the Inline Quality Control of Plastic Pipes

Pipe inspection with terahertz technology from Fraunhofer ITWM enables non-contact, non-destructive inline measurement of the wall thickness of smooth and corrugated pipes directly in the production process. The system measures at four freely selectable positions and can be flexibly adapted to different pipe diameters and materials. The technology recognizes important parameters such as wall thickness, diameter, ovality and layer structure. The aim is to ensure quality assurance at an early stage in order to use material efficiently and avoid rejects. Even small savings in wall thickness lead to major economic benefits.

»We use terahertz time-domain spectroscopy and FMCW methods for this, which deliver precise results regardless of temperature and material – in contrast to classic ultrasound or X-ray methods,« explains Dr. Joachim Jonuscheit from Fraunhofer ITWM.

PU-Expansionssimulation mit FOAM — © Fraunhofer ITWM
Expansion simulation of the polyurethane foam with the FOAM software for the production of a cool box.

Color-coded fiber orientation for entire component. Left: Moldflow mesh. Right: Abaqus mesh. Grey areas indicate parts that are not made of PP-LGF30. — © Fraunhofer ITWM
Researchers at the Fraunhofer ITWM are using a digital twin to optimize the lye container of a washing machine. Here you can see the color-coded fiber alignment for the entire component.

Simulation of Spinning Processes for Optimized Filaments

In the »VISPI – Virtual Spinning« project, scientists at the Fraunhofer ITWM are developing simulation software that digitally maps and optimizes industrial spinning processes for high-tech fibers. The complex physical processes involved in spinning – for example in the production of glass wool or polymer fibers – are simulated as realistically as possible to improve material consumption, energy requirements and product quality. The VISPI software allows the input of process parameters such as nozzle geometry, mass flow, temperature and viscosity of polymer. It models the flow dynamics and the response of the fibers on the air flow and analyzes turbulence, dead zones and the cooling behavior of the filaments. An integrated material database module supports the selection of suitable polymers.

»We use VISPI to test and improve complex spinning processes virtually. This saves resources and increases product quality. Companies benefit from fewer bad investments during upscaling and increase their competitiveness,« says Dr. Walter Arne, one of the software's developers.

The projects and technologies of the Fraunhofer ITWM show how digital simulations and precise measurement technology contribute to the optimization of materials, processes and products - from foam filling to fiber processes to pipe inspection. This results in more resource-efficient developments, higher quality and economic advantages for the industry. Visit us at the joint Fraunhofer stand in hall 7, level 0, stand SC05.