It’s All About the Surface – Simulation for Multiscale Micro- And Nano-Injection Molding

Simulation Tool for Sustainable, Functionalized Plastic Surfaces

Press Release / March 24, 2026

A new simulation tool for plastics processors is designed to make the development of functionalized, recyclable components faster, more cost-effective, and more resource-efficient. The Fraunhofer Institute for Microstructure of Materials IMWS in Halle (Saale) and the Fraunhofer Institute for Industrial and Economic Mathematics ITWM in Kaiserslautern are combining their expertise in the areas of patented micro-/nanostructuring and cross-scale simulation software.

The surfaces of plastic components often require specific characteristics for applications in the automotive, medical technology, or packaging industries – for example, to enable defined adhesive forces, controlled wettability, or optical properties such as diffuse reflection. Currently, these functions are mostly achieved using additives or coatings. This is detrimental to recyclability, as the plastics are then no longer homogeneous. Additionally, process costs increase. A high-performance alternative is purely morphological surface functionalization, as developed at Fraunhofer IMWS: micro- and nanostructures directly generate the desired surface properties.

»With this patented process, which is also suitable for injection molding, we can structure plastic surfaces over large areas in a bionically inspired way – without any chemical additives at all,« says Annika Thormann, project manager at Fraunhofer IMWS. »Thanks to the new simulation tool, we are making this technology more quickly accessible to the plastics processing industry and laying the groundwork for recyclable, resource-efficient products.«

MESHFREE Maps the Injection Molding Process From the Nanoscale to the Macroscale

In the »3-ScaleSim« project, the two Fraunhofer Institutes are developing a cross-scale simulation tool based on the mesh-free MESHFREE software, which was developed by Fraunhofer ITWM and awarded the Joseph von Fraunhofer Prize in 2024. The digital twin of the injection molding process links structural design at the macro, micro, and nanoscale with material data and process parameters such as pressure and temperature. A nano-micro-macro database, along with accompanying experiments at Fraunhofer IMWS, enables the iterative validation and refinement of the models.

The goal is to largely replace time-consuming feasibility studies with virtual experiments and to reliably evaluate micro- and nanostructuring as early as the initial stages of development. »By extending MESHFREE from the macroscale to the micro- and nanoscales, we are making the entire injection molding process fully simulatable for the first time,« explains Isabel Michel, project manager at Fraunhofer ITWM. »This provides companies with precise predictions regarding structural features and surface properties – while significantly reducing development times.«

Shorter Development Times for Smes and Applications Ranging From Automotive to Medical Technology

The project is expected to result in a comprehensive process demonstrator comprising micro-/nanostructured injection-molded parts and the associated simulation tool. Plastics processors, particularly small and medium-sized enterprises, will be able to digitally test different variations of mold designs, polymers, and process windows before investing in production. This reduces costs and risks, shortens development cycles, and accelerates decision-making.

The technology addresses key challenges in the plastics industry: resource conservation, recyclability, and high functional requirements for plastic surfaces. The plastics processing industry can benefit significantly from this in application areas such as consumer goods, medical technology, packaging, and the automotive sector. In the future, the database-supported approach can also be applied to other materials, such as metals.