Science

Science enables us to continuously develop plastics as a material, open up new areas of application and make it fit for a future that protects the environment and conserves resources. We present the latest research projects and findings. Fascinating.

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Results (45)

  • Fluorinated polymers for the circular economy

    How fluorine can be regained sustainably Exklusiv für K-Mag Fluorinated polymers are often used in rain coats or pans. However, recycling these polymers has not been economical to date. Copyright: astrakanimages 27.11.2024 Fluorinated polymers are valued in everyday life for their non-stick properties and durability, among other things. However, this becomes a challenge when it comes to recycling them. A research team at the University of Bayreuth has investigated a solution to this problem. Their concept involves chemically transforming fluorinated plastics and thereby recovering the fluorine. In this interview, Dr. Alex Plajer explains what the new fluorinated polymers are made of, what they could be used for in the future and what opportunities this opens up for the circular economy. Dr. Plajer, what are the key properties of the new class of fluorinated polymers? Dr. Alex J. Plajer: The new fluorinated polymers that we are researching are a little more slippery and water-repellent than polyesters without fluorine. However, these polymers are not yet competitive with Teflon, Nafion or similar. In the study, we looked in particular at the advantage of chemical recycling of fluorinated plastics, as this process is not yet very popular for these plastics. New concepts are therefore needed, and we are currently working on this. With the new concept, we are chemically transforming plastics so that they can ultimately be reused as raw materials. How do the new polymers differ from previously fluorinated polymers? Dr. Plajer: The chains of the vast majority of commercialized fluoroplastics (Teflo, Nafion, PVDF) consist only of carbon atoms, and the fluorine depends on these chains. Our plastics, on the other hand, contain ester bridges that make our material degradable and recyclable. Such products are not yet available on the market. How does this accelerated degradation process work? Dr. Plajer: We add a very strong base to the fluoroplastics and can thus extract the fluorine. This does not work with water or acids, but only with very strong bases. What opportunities does the recovered fluorine open up for the circular economy? Dr. Plajer: The chemical industry wants solutions that are easy to integrate, i.e. they want to adapt their processes as little as possible. In other words, companies need exactly the same basic materials that they already use so that they don't have to adapt the process for producing fluorinated chemicals. The degradation products we generate are in exactly the form that the chemical industry needs them. Recycled fluorinated polymers cannot yet compete with conventional products in terms of price. Researchers are working to change this. Copyright: hiv360 What steps still need to be taken before you can really move from the laboratory phase to implementation? Dr. Plajer: One challenge is certainly the length of the chains: our polymers are not yet long enough. We know that we can manufacture these products and that they offer the possibility of chemical recycling, but the chains are not yet particularly long. We are currently an order of magnitude below what other plastics show that could be commercialized. We therefore need to improve the chemical manufacturing process for polymers. The second challenge is the price: our products simply cannot yet compete with other plastics, and recycling is also not yet financially viable in some cases because the prices for non-sustainable polymers are so low. The production of our basic building blocks must therefore become cheaper in order to be able to compete. Where do you see the greatest potential for the use of these new fluorinated polymers in everyday life? Dr. Plajer: That's a tough question, because we actually like using plastic so much because it is non-degradable, for example for Goretex clothing or Teflon heart valves. I see our products being most useful in short-lived applications, for example as coatings. However, our applications are not yet ready for commercialization. Our main concern is to rethink the idea of recycling and the sustainability concept of fluorine. Because if fluorinated chemicals are so difficult to break down and there is no recycling strategy for them, then these chemicals simply go back into nature and can no longer be recovered. That's why we need to handle them responsibly. How do you see the future of flourished polymers in terms of environmental compatibility and sustainability, especially when you look at the current criticism of perpetual chemicals? Dr. Plajer: There are special applications where it will not be possible to replace flourished chemicals: Teflon in a technical seal or Nafion in a fuel cell cannot be replaced with the current state of the art. Then again, there are also applications where these fluorinated substances are unnecessary – in pizza boxes or dental floss, for example. Degradable alternatives could also be used here, which of course still have the advantage of fluorination, but also have the corresponding degradation mechanisms. Nevertheless, just because a polymer is degradable does not mean that it should be used irresponsibly. When we talk about "degradable plastic bags", we are signaling to society that you can simply dispose of them in the forest. Of course that's not the case! We lose the raw material, the material and all the work that has gone into this product. Kyra Molinari (Redaktion K-Mag) More around Science

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  • Intelligent Material with Potential: Shape Memory Polyurethane Enables New Applications

    Fraunhofer IAP has developed film foam that promises safer, more sustainable and more efficient solutions for industry and technology Exclusively for K-Mag Function on demand: The new film foam from the Fraunhofer IAP can be stored as a film to save space and transforms into a stable foam structure when heated. Copyright: Fraunhofer IAP / Jadwiga Galties 07.05.2025 A film that remembers its original shape and turns into foam "at the touch of a button"? This is exactly what a research team at the Fraunhofer IAP is working on. The combination of polyurethane and the shape memory effect results in a completely new material that can be stored as a space-saving film and transforms back into a high-performance foam structure when required. In an interview with K-Mag, Dr Thorsten Pretsch explains how this material works, what advantages it offers compared to classic PU foams – and where the greatest potential for industry, sustainability and safety lies. Shape Memory Meets Foam: Potential and Advantages Dr Thorsten Pretsch conducts research at the Fraunhofer IAP on innovative materials such as foil foam with shape memory effect. Copyright: Fraunhofer IAP Dr Pretsch, PU foam is a widely used material. What motivated you to rethink this material? Dr Thorsten Pretsch: The motivation to rethink PU foam stems from the potential to develop innovative properties and applications. As far as we know, there has never before been a process for producing a film from a shape memory polymer foam and then transforming it back into the foam by heating it. The programming results in a thermally switchable semi-finished product in which the information about the foam structure is stored. The product bears the name FOIM, a neologism made up of the English terms "foil" and "foam". What specific advantages does the foil foam offer – especially in comparison to conventional PU foams? Pretsch: Strict regulations and protective measures apply to the handling of isocyanates in the construction industry, for example, as they are toxic and have sensitizing effects on the respiratory tract and skin. In addition, some isocyanates are suspected of causing cancer. The newly developed film transforms into polyurethane foam simply by applying heat, without reacting chemically. This is why we refer to this type of foam production as "thermal foaming". Our solution therefore offers a healthy alternative that focuses on both personal safety and environmental protection. Versatile: This is How the Properties of the Foam Can Be Specifically Controlled Which specific parameters can be adjusted – and how do they affect functionality in different applications? Pretsch: First of all, the chemical formulation can be used to influence the thermal and mechanical properties of the foam. Another important factor is the density, which influences the strength and load-bearing capacity of the foam. A higher density ensures greater stability, while a lower density enables lighter and more flexible applications. High-density foam is therefore well suited for structural applications, while low-density foam is predestined for use in packaging or upholstery. In addition, additives can be incorporated into the film foam to improve its properties, for example in terms of fire resistance, UV resistance or elastic properties. Such modified foams are particularly beneficial in more demanding environments where there are additional safety or performance requirements. The degree of mold recovery when the shape memory effect is triggered also plays a crucial role as it influences the final structure and mechanical properties. This can be important in applications that require a high degree of adaptability, such as the fixing of fragile objects, or in the case of thermally sequentially adjustable damping or insulation. In short, the targeted adjustment of these parameters enables the film foam to be optimized for a wide range of applications. Game Changer in the Application - from Construction to Medical Technology Are there application scenarios in which foil foam represents a real game changer? Pretsch: It could actually be a game changer in several application scenarios. For example, the space-saving storage and simplified transportation enable more efficient logistics and cost savings. In addition, the gradually adjustable property profiles allow flexible adaptation to different applications when resetting the mold, which makes handling easier. In sectors such as the automotive, construction and packaging industries, the lower system costs and compact shape of the film foam could offer significant advantages. Innovative applications in medical technology and pharmaceuticals, such as drug delivery systems, could also benefit from the unique properties of the film foam. More on this topic in K-Mag: In this interview, Dr Thorsten Pretsch talks about the extent to which shape memory polymers enable more efficient tooth correction. Elena Blume (Editorial team K-Mag) More around Science

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  • Innovation in collaboration: How a network aims to revitalize the plastics and rubber industry

    The Polymer Industry Cluster in Ohio connects industry, research, and start-ups Exclusively for K-Mag 17.09.2025 The challenges facing the plastics and rubber industry are global – and sometimes difficult for individual players to overcome. The Polymer Industry Cluster , based in Akron, Ohio, USA, therefore focuses on collaboration: an alliance of companies, research institutions, start-ups, and investors working together to drive innovation. The focus is on sustainable materials, scalable technologies, and pre-competitive platforms that reduce risks and promote solutions for the circular economy. At K 2025, the cluster will present its innovation accelerator “Synthe6,” among other things, and actively seek exchange with international partners. With an eye toward K 2025, we spoke with Executive Director and Chief Innovation Officer Hans Dorfi , PhD. Research ecosystem for materials: The Polymer Industry Cluster What does your company stand for - and what particularly characterises your product or service portfolio? Hans Dorfi: The Polymer Industry Cluster is not a single company, but an ecosystem based in Greater Akron and Northeast Ohio that unites manufacturers, researchers, entrepreneurs, and investors to solve the shared challenges of the polymer industry. We stand for collaborative innovation, sustainability, and competitiveness. Our portfolio is characterized by programs that accelerate advanced materials R&D, connect startups with scale-up resources, de-risk emerging technologies, and foster circular economy solutions. Synthe6 and Co.: Innovation platforms for sustainable polymer solutions What topic or innovation are you bringing to K 2025 – and why is it relevant for the industry? Dorfi: We are showcasing our platforms for innovation and collaboration, the Synthe6 accelerator, and our focus on building the next generation ecosystem in partnership with industry for advanced and sustainable polymer solutions. The plastics and rubber industry of the future is circular, innovative, and collaborative—turning material challenges into global solutions that benefit mankind. Hans Dorfi, PhD, Executive Director and Chief Innovation Officer Polymer Industry Cluster Cluster-based collaboration as the key to material innovation What would you like to talk to visitors about at K 2025 – what is particularly important to you? Dorfi: We want to talk about how collaboration accelerates innovation. Many of the industry’s toughest challenges — end-of-life solutions, scaling bio-based alternatives, or deploying advanced composites — are bigger than any one company. By pooling resources and expertise within a cluster, we can create pre-competitive platforms that reduce risk, shorten timelines, and create shared value for all participants. If you are interested in making an investment in the United States, the Polymer Industry Cluster presents your company with a collaborative environment that will help your business grow – whether through innovation, commercialization, or scaling to meet North American needs and demands. K 2025 as an opportunity for international research partnerships What do you expect from your participation at K 2025 and what are you personally looking forward to the most? Dorfi: We expect to forge international partnerships that link our U.S.-based innovation ecosystem with global leaders in materials, manufacturing, and sustainability. Personally, we look forward to connecting with innovators and partners interested in collaboration, sharing success stories from our regional cluster, and learning how others are advancing sustainable materials at scale. We encourage any businesses visiting or exhibiting at K 2025 to stop at our booth in Hall 13 at 13A89-13 to speak to the Akron USA economic development team to learn more about the Polymer Industry Cluster and how we can aid your business’s entry and growth in the North American. Exhibitors & products around plastics processing Processing technologies Follow on treatment of plastics products Supplying Product groups Products To all exhibitors in this category The portrait was generated by AI. Editor: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance Hans Dorfi, PhD, Executive Director and Chief Innovation Officer of the Polymer Industry Cluster, explains how the US ecosystem connects research, companies, and start-ups. The focus is on sustainable materials, the circular economy, and the “Synthe6” innovation platform. At K 2025, the cluster is looking for international partners to jointly develop solutions for the plastics industry of tomorrow. More around Science

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  • Protective bacteria: Biopolymer coating for textiles

    Interview with Dr Thomas Stegmaier and Dr Thomas Hettich, Competence Centre Textile Chemistry, Environment & Energy, German Institutes of Textile and Fibre Research Denkendorf (DITF) Exclusively for K-Mag The cotton yarn is coated with PHA using a coating nozzle. Copyright: DITF 03.05.2024 It defies wind and weather and protects us from a wide range of environmental influences: Functional clothing. Special coatings are responsible for this. Polyacrylates or polyurethanes, which are based on crude oil and therefore a finite resource, are often used for this purpose. The German Institutes of Textile and Fibre Research Denkendorf (DITF) are therefore researching alternatives from renewable sources – including polymers from bacteria. Dr Thomas Stegmaier. Copyright: DITF In an interview with K-Mag, Dr Thomas Stegmaier and Dr Thomas Hettich talk about textile coatings made from bacteria, their production and advantages. How did you come up with the idea of using biopolymers from bacteria for textile coatings? Dr Thomas Stegmaier and Dr Thomas Hettich: One of our research focuses is on replacing fossil-based polymers with renewable raw materials that can be used to produce more sustainable polymers for textiles. This includes both fibres and coatings. We are keeping a very close eye on developments in biotechnology and the agricultural sector, which are very dynamic when it comes to finding suitable raw materials. Some bacteria have the particular advantage that they consist of a suitable meltable biopolymer with a high weight proportion of up to 50%. The task in the harvest is then to separate this polymer from the remaining biomass. Here we work closely with our partner, the Fraunhofer IGB, which cultivates highly efficient bacterial cultures. Dr Thomas Hettich. Copyright: DITF Can you describe the process of how PHA is produced and which factors influence the properties of the end product? Stegmaier & Hettich: Some bacterial strains store PHA as energy reserves – a comparison can be made with humans who store fat deposits. The decisive factor for the creation of these reserves is that they are not adequately supplied with all nutrients, but are, for example, undersupplied with nitrogen and oversupplied with sugar or fatty acids. The resulting surplus of carbon and hydrogen from sugar or fatty acids is converted into PHA by the bacteria. Depending on the bacterial strain, PHA differs in its repeating unit, molecular weight, polydispersity, viscosity and melting point. The molten PHA is filled into the squeegee using a hot glue gun. Copyright: DITF How do the properties and applications of polyhydroxyalkanoates (PHA) differ from traditional petroleum-based coating materials? Stegmaier & Hettich: Petroleum-based coatings for textiles have a long history of development and have excellent properties. A high level of waterproofness for clothing, for example, can only be achieved with a coating. The PHAs available to date have good basic characteristics, which we utilise to our advantage. However, many properties still need to be developed so that the coated textiles can fulfil their function. More articles on the subject of textiles in K-Mag: Covestro launches Impranil® CQ DLU, an innovative textile coating. There are many reasons why plastics are indispensable in the modern textile industry. Huafeng, Cyclone and Covestro produce sportswear with a reduced carbon footprint. The cotton fabric is coated with molten PHA using a squeegee. Copyright: DITF What technical and ecological advantages do textiles coated with PHA offer, particularly in terms of wind and water resistance? Stegmaier & Hettich: The advantages lie in the pronounced sustainability. Until now, windproof and waterproof textiles have been made from petroleum-based raw materials or partly from recycled materials. The high barrier effect of PHA against wind and water has already been demonstrated in films made from it. What challenges had to be overcome in the development of PHA-based coatings for technical textiles? Stegmaier & Hettich: Conventional coating systems are produced with polymers where the synthesis is already designed with a view to the properties required later in the product. This is not easily possible with the biosynthesis of PHA. Cotton yarn coated with PHA. Copyright: DITF What other research and development goals are the DITF pursuing in the field of bio-based textile coatings? Stegmaier & Hettich: In the long term, we would like to identify technical possibilities for replacing coating systems that are currently based on fossil resources with bio-based systems. These polymer systems are generally also biodegradable, so that the problem of microplastics in our environment can be tackled. Elena Blume (Editorial team K-Mag) More around Science

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  • Turning a problem into a solution: Wasser 3.0 studies ways to remove microplastics from water without a filter

    Interview with Dr. Katrin Schuhen, inventor, founder, and CEO of Wasser 3.0 Exclusively for K-MAG Source: PantherMedia / mproduction 15.12.2021 Plastic is an important material and a virtually irreplaceable component in many products. However, the breakdown and disposal of plastics after use also goes along with microplastics. At the end of its life cycle, plastic material first ends up in the environment and then comes back to us: According to a study by the University of Newcastle , tiny particles of microplastic can enter our bodies via drinking water or certain foods. Dr. Katrin Schuhen; Source: Wasser 3.0 That is why it is imperative to thwart the spread of microplastic pollution. It is also the stated goal of the non-profit company Wasser 3.0 (English: Water 3.0). In this interview, founder Dr. Katrin Schuhen explains how the company's "4th Treatment Step plus" project (German: "4. Reinigungsstufe plus") studies the concentration of microplastics in municipal wastewater treatment plants. The company also delivers a way to remove the harmful substance. Dr. Schuhen, what is the focus of your project titled "4th Treatment Step Plus"? Dr. Katrin Schuhen: While some wastewater treatment plants already implement a fourth treatment step to remove micropollutants such as pharmaceuticals, pesticides or PFAS, microplastics are neither regulated by law nor high on the agenda of wastewater treatment or water protection facilities. Yet we definitely know that municipal sewage treatment plants encounter significant microplastics pollution. Our 12-month long-term study at the municipal wastewater treatment plant Landau-Mörlheim studies both classes of pollutants for the first time: the dissolved organic chemical compounds which include micropollutants, and plastic particulate contaminants. The latter are known as microplastics, referring to fragments of any type of plastic less than 5 mm (0.20 in) in length. Our Wasser 3.0 PE-X® process simultaneously removes microplastics and micropollutants from wastewater. We also apply our new detection method to track water pollution by microplastics continuously. By adding the data from micropollutant monitoring, we can also continuously adapt and optimize our removal technology. This gives us key data records pertaining to microplastic pollution at a municipal wastewater treatment plant. Due to the lack of standard analytical methods, there have been big gaps in knowledge and data in this area. One of our goals is to close these gaps. In short, we use our detection method to analyze the real extent of a problem, which we subsequently solve with our removal technology. The agglomerates can be easily removed with a sieve. Source: Wasser 3.0 Can you explain the technology and how it works? Schuhen: Wasser 3.0 applies three chemical concepts based on the principles of green chemistry, designed to remove inorganic chemical, organic chemical and microplastic contaminants from water. We always aim for zero pollutants in water. This is also why we called our company Wasser 3.0. We apply the principle of "clump and skim" to remove harmful microplastics: We use a simple process to add hybrid silica gels that are not harmful to health to the contaminated water. Once stirred, the hybrid silica gels clump together with the microplastics and micropollutants and form agglomerates that resemble popcorn. These float on top of the water and get separated using a skimmer and no filters. One can also use coarse-pored filters for large agglomerates. The adaptability of the hybrid silica gels is the key to the success of our process. Individual adaptation enables us to create custom solutions for different types of pollution and types of water. We achieve reproducible elimination rates of over 95 percent for microplastics. For micropollutants, we follow the guidelines of the German National Water Strategy, which stipulates a minimum 80 percent removal efficiency for micropollutants by wastewater treatment facilities. Wasser 3.0 PE-X® is a meaningful and value-added application not only as it pertains to municipal wastewater but also when it comes to industrial processes, surface waters, and systems that use saltwater such as seawater desalination or sea salt extraction. Especially in industrial processes, our implementation immediately stops microplastics from entering the water cycle. At this juncture, we not only close loops in a circular process flow, but our sustainable process design also delivers economic incentives for environmental protection. Exhibitors and products around research and science: Science and consulting Trade associations Technical books Professional periodicals Trade directories What knowledge have you gained from the project? Schuhen: As part of our project, we have been sampling microplastic and micropollutant concentrations continuously at different steps in the water treatment process since June. The multifaceted data is currently being analyzed. The first series of tests revealed removal efficiencies of 95 percent for microplastics. This data underpins the findings from previous tests of our method. It bears repeating that despite many claims to the contrary, microplastics are not completely removed from wastewater via sewage sludge and then burned along with the sludge. Vast amounts of plastic participles still evade the water treatment steps, allowing microplastics to enter the environment. The initial findings of the long-term study support this statement. While sewage treatment plants can remove microplastics, they are microplastics emitters at the same time. A fact that should be kept in mind in a quest for solutions that won't spell big problems for future generations. How will your research findings impact the future of microplastic removal? Schuhen: The environmental and health risks of microplastics are the subject of heated debates in society. Water purification and its effects on biodiversity, climate change, and public health is an important issue and one that I believe must transition more quickly from problem statement to proactive steps and forward-thinking action. We hope our actionable insights into the detection and removal of microplastics will move the issue higher up on the political priority list, give the problem more visibility and promote faster action. The successful evaluation completion of our detection solution for continuous process control is a quantum leap in microplastics because it exhibits a much quicker, more efficient, and more cost-effective way to remove microplastics than conventional detection methods. All told, it lends itself to support a standardized approach to data collection on microplastic water pollution. Standardization in this area would have far-reaching consequences for the political discourse pertaining to thresholds and their adoption. The willingness and prospects of a solution means microplastics must become a higher priority on the political agenda. We also hope to see a shift in mindset when it comes to thermal recycling of sewage sludge. Due to the high pollution levels in sewage sludge, it seems to be a more environmentally friendly and healthy approach compared to its application as a commercial fertilizer. I believe we are missing out on a valuable resource in this case. If the findings of our removal rates are further corroborated, we will enable microplastic and micropollutant removal and facilitate simultaneous sewage sludge protection. This could also yield additional uses in the future. Source: Wasser 3.0 What are the focal points of your work? What goals are you pursuing in your research over the next years? Schuhen: The core strategy of our work is to detect| remove | reuse microplastics and micropollutants in our water in a holistic manner. Our systemic approach navigates a framework geared towards the common good as it pertains to research, education, communication, and technology development. The 4th Treatment Step plus in municipal sewage treatment plants is a milestone for us and a key lever for water without microplastics and micropollutants. Another milestone is to prevent microplastics and micropollutants from entering the water cycle in the first place, resulting in the need to remove them from the wastewater in municipal sewage treatment facilities. We are collaborating with various industry sectors in flagship projects dealing with microplastic-contaminated process and wastewater. We are adapting our Wasser 3.0 PE-X® process in feasibility studies, are continuing to evaluate our detection method and ways to reuse so-called waste products. In the years to come, research of microplastics and micropollutants will continue to grow in importance. Not only do we require new technologies that foster sustainability and help drive circular economy, but we also urgently need a more comparable and reliable database to engage policymakers and industry to inspire action. The key to success is applied research that embraces innovation transfer, education, and public awareness. Wasser 3.0 covers these aspects. After all, we don't just need one but many solutions to eliminate microplastics and micropollutants from water. These must come from policymakers, industry, science, civil society, from local and international stakeholders, from individuals and groups of people. Kyra Molinari (Editorial team K-MAG) More Science

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  • ProQuIV optimizes the production of nonwoven masks

    Quelle: jirkaejc 09.01.2023 Producing infection control clothing requires a lot of energy and uses lots of material resources. Fraunhofer researchers have now developed a technology which helps to save materials and energy when producing nonwovens. A digital twin controls key manufacturing process parameters on the basis of mathematical modeling. As well as improving mask manufacturing, the ProQuIV solution can also be used to optimize the production parameters for other applications involving these versatile technical textiles, enabling manufacturers to respond flexibly to customer requests and changes in the market. The nonwovens used for FFP-2 masks must filter at least 94 percent of aerosols, particles or viruses according to DIN. Copyright: Freudenberg Performance Materials Nonwoven infection control masks were being used in their millions even before the COVID-19 pandemic and are regarded as simple mass-produced items. Nevertheless, the manufacturing process used to make them needs to meet strict requirements regarding precision and reliability. According to DIN (the German Institute for Standardization), the nonwoven in the mask must filter out at least 94 percent of the aerosols in the case of the FFP-2 mask and 99 percent in the case of the FFP-3 version. At the same time, the mask must let enough air through to ensure that the wearer can still breathe properly. Many manufacturers are looking for ways to optimize the manufacturing process. Furthermore, production needs to be made more flexible so that companies are able to process and deliver versatile nonwovens for a wide range of different applications and sectors. ProQuIV, the solution developed by the Fraunhofer Institute for Industrial Mathematics ITWM in Kaiserslautern, fulfills both of these aims. The abbreviation "ProQuIV" stands for "Production and Quality Optimization of Nonwoven Infection Control Clothing" (Produktions- und Qualitätsoptimierung von Infektionsschutzkleidung aus Vliesstoffen). The basic idea is that manufacturing process parameters are characterized with regard to their impact on the uniformity of the nonwoven, and this impact is then linked to properties of the end product; for example, a protective mask. This model chain links all relevant parameters to an image analysis and creates a digital twin of the production process. The digital twin enables real-time monitoring and automatic control of nonwoven manufacturing and thus makes it possible to harness potential for optimization. Dr. Ralf Kirsch, who works in the Flow and Material Simulation department and heads up the Filtration and Separation team, explains: "With ProQuIV, the manufacturers need less material overall, and they save energy. And the quality of the end product is guaranteed at all times." Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Nonwoven manufacturing with heat and air flow Nonwovens for filtration applications are manufactured in what is known as the meltblown process. This involves melting down plastics such as polypropylene and forcing them through nozzles so they come out in the form of threads referred to as filaments. The filaments are picked up on two sides by air flows which carry them forward almost at the speed of sound and swirl them around before depositing them on a collection belt. This makes the filaments even thinner: By the end of the process, their thickness is in the micrometer or even submicrometer range. They are then cooled, and binding agents are added in order to create the nonwoven. The more effectively the temperature, air speed and belt speed are coordinated with each other, the more uniform the distribution of the fibers at the end and therefore the more homogeneous the material will appear when examined under a transmitted light microscope. Lighter and darker areas can thereby be identified — this is referred to by experts as cloudiness. The Fraunhofer team has developed a method to measure a cloudiness index on the basis of image data. The light areas have a low fiber volume ratio, which means that they are less dense and have a lower filtration rate. Darker areas have a higher fiber volume and therefore a higher filtration rate. On the other hand, the higher air flow resistance in these areas means that they filter a smaller proportion of the air that is breathed in. A larger proportion of the air flows through the more open areas which have a less effective filtration effect. The transmitted light image from the microscope shows the distribution of the fibers in the nonwoven. Copyright: Fraunhofer ITWM Production process with real-time control In the case of ProQuIV, the transmitted light images from the microscope are used to calibrate the models prior to use. The experts analyze the current condition of the textile sample and use this information to draw conclusions about how to optimize the system — for example, by increasing the temperature, reducing the belt speed or adjusting the strength of the air flows. “One of the key aims of our research project was to link central parameters such as filtration rate, flow resistance and cloudiness of a material with each other and to use this basis to generate a method which models all of the variables in the production process mathematically,” says Kirsch. The digital twin monitors and controls the ongoing production process in real time. If the system deviates slightly from where it should be — for example, if the temperature is too high — the settings are corrected automatically within seconds. The simulation software maps the relationship between the control of the meltblown process and the uniformity of the nonwoven. Copyright: Fraunhofer ITWM Fast and efficient manufacturing "This means that it is not necessary to interrupt production, take material samples and readjust the machines. Once the models have been calibrated, the manufacturer can be confident that the nonwoven coming off the belt complies with the specifications and quality standards," explains Kirsch. ProQuIV makes production much more efficient — there is less material waste, and the energy consumption is also reduced. Another advantage is that it allows manufacturers to develop new nonwoven-based products quickly — all they have to do is change the target specifications in the modeling and adjust the parameters. This enables production companies to respond flexibly to customer requests or market trends. This might sound logical but can be quite complex when it comes to development. The way that the values for filtration performance and flow resistance increase, for example, is not linear at all, and they are not proportional to the fiber volume ratio either. This means that doubling the filament density does not result in double the filtration performance and flow resistance — the relationship between the parameters is much more complex than that. "This is precisely why the mathematical modeling is so important. It helps us to understand the complex relationship between the individual process parameters," says ITWM researcher Kirsch. The researchers are able to draw on their extensive expertise in simulation and modeling for this work. More applications are possible The next step for the Fraunhofer team is to reduce the breathing resistance of the nonwovens for the wearer without impairing the protective effect. This is made possible by electrically charging the fibers and employing a principle similar to that of a feather duster. The electric charge causes the textile fabric to attract the tiniest of particles which could otherwise slip through the pores. For this purpose, the strength of the electrostatic charge is integrated into the modeling as a parameter. The Fraunhofer researchers’ plans for the application of this method extend far beyond masks and air filters. Their technology is generally applicable to the production of nonwovens — for example, it can also be used in materials for the filtration of liquids. Furthermore, ProQuIV methods can be used to optimize the manufacture of nonwovens used in sound-insulating applications. Quelle Fraunhofer-Gesellschaft More Science

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  • Fraunhofer researchers develop recyclable, fiber-reinforced material made from 100 percent bio-based polylactic acid

    Fraunhofer IAP's novel biobased PLA fibers make it possible to produce a fiber composite made entirely of PLA that can be easily recycled. Photo: Fraunhofer IAP 17.05.2021 "Packaging made from bio-based plastics has long been established. We are now supporting the further development of these materials for new areas of application. If in the future the market also offers plant-based materials for technically demanding tasks such as vehicle construction, the bioeconomy will take a decisive step forward," explained Uwe Feiler, Parliamentary State Secretary at the Federal Ministry of Food and Agriculture, in Potsdam today. The occasion was the handover of a grant to the Fraunhofer Institute for Applied Polymer Research IAP . The Fraunhofer IAP wants to develop a composite material that consists entirely of bio-based polylactic acid (PLA) and is significantly easier to recycle than conventional fiber composites. The German Federal Ministry of Food and Agriculture (BMEL) is intensively promoting the development of biomaterials as part of its Renewable Resources funding program. More than 100 projects are currently underway, covering a wide range of topics: from plastics that are degradable in the sea to natural fiber-reinforced lightweight components for the automotive sector. The projects are supported by the Agency for Renewable Resources, the BMEL project management agency responsible for the Renewable Resources funding program. Easier recycling of fiber-reinforced plastics Handover of the grant (from left: Prof. Alexander Böker, Fraunhofer IAP Director; Uwe Feiler, Parliamentary State Secretary BMEL; Dr. André Lehmann, Fiber Technology Department at Fraunhofer IAP; Prof. Johannes Ganster, Biopolymers Research Unit at Fraunhofer IAP). Photo: Fraunhofer IAP/Till Budde PLA is one of the particularly promising bio-based materials. The global market for this polymer is growing by around 10 percent a year. PLA is also used, among other things, as a matrix in fiber-reinforced plastics. In these mechanically resilient plastics, reinforcing fibers are embedded in a plastic matrix. The Fraunhofer IAP project is now focusing on these reinforcing fibers: "We are further developing our PLA fibers in order to transfer them to industrial scale together with partners from industry. These fibers are ideally suited for reinforcing PLA plastics. The resulting self-reinforcing single-component composite promises great recycling benefits. Since the fiber and the matrix of PLA are chemically identical, complex separation steps are not necessary," explains Dr. André Lehmann, expert for fiber technology at Fraunhofer IAP. Novel PLA fibers and films are more thermally stable The challenge with this approach is that conventional PLA has a relatively low temperature resistance. Technical fibers can be produced most economically using the melt spinning process. The Fraunhofer IAP team is now using more thermally stable stereocomplex PLA (sc-PLA) for the fibers. The term stereocomplex refers to a special crystal structure that the PLA molecules can form. Sc-PLA fibers have a melting point that is 40 - 50 °C higher and can therefore withstand the incorporation process in a matrix made of conventional PLA. In the project, the researchers are developing and optimizing a melt spinning process for sc-PLA filament yarns. The partner in this work package is Trevira GmbH, a manufacturer of technical and textile fiber and filament yarn specialties that are in demand from automotive suppliers and contract furnishers, among others. Furthermore, the development of a manufacturing process for sc-PLA reinforced flat films is planned. The international adhesive tape manufacturer tesa SE is participating in this task, and will test the suitability of sc-PLA films as adhesive foils. In a third work package, the Fraunhofer IAP will finally process the filaments in a double pultrusion process to produce granules suitable for injection molding. Bio-based solutions for the automotive and textile industries The scientists led by Dr. André Lehmann are certain that the self-reinforced PLA material can conquer many new areas of application. The automotive and textile industries are already showing interest in bio-based materials that are also easier to recycle. In terms of price, PLA would already be competitive here, and now the material is also to be made technically fit for the new tasks. Professor Alexander Böker, head of Fraunhofer IAP, says: "The steadily growing demand from industry for sustainable solutions underlines how important it is to develop biobased and at the same time high-performance materials. With our research, we are also actively driving the development of a sustainable and functioning circular economy and therefore very much welcome the support from the federal government." Information on the project is available at fnr.de under the funding code 2220NR297X. Source Fraunhofer Institute for Applied Polymer Research IAP More Science

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  • Plastics of the future will live many past lives, thanks to chemical recycling

    One day in the not-too-distant future, the plastics in our satellites, cars and electronics may all be living their second, 25th or 250th lives Source: Fahroni 01.12.2022 New research from the Colorado University Boulder, published in Nature Chemistry , details how a class of durable plastics widely used in the aerospace and microelectronics industries can be chemically broken down into their most basic building blocks and then formed once again into the same material. It's a major step in the development of repairable and fully recyclable network polymers, a particularly challenging material to recycle, as it is designed to hold its shape and integrity in extreme heat and other harsh conditions. The study documents how this type of plastic can be perpetually broken down and remade, without sacrificing its desired physical properties. "We are thinking outside the box, about different ways of breaking chemical bonds," said Wei Zhang, lead author of the study and chair of the chemistry department. "Our chemical methods can help create new technologies and new materials, as well as be utilized to help solve the existing plastic materials crisis." Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates A detail of recycled plastic. Source: Patrick Campbell/CU Boulder Their results also suggest that revisiting the chemical structures of other plastic materials could lead to similar discoveries of how to fully break down and rebuild their chemical bonds, enabling the circular production of more plastic materials in our daily lives. In the mid-20th century, plastics were ubiquitously adopted in almost every industry and part of life as they are extremely convenient, functional and cheap. But half a century later, after exponential demand and production, plastics pose a major problem to the health of the planet and to people. The production of plastics requires large amounts of oil and the burning of fossil fuels. Disposable plastics create hundreds of millions of tons of waste every year, which ends up in landfills, oceans and even in our bodies, in the form of microplastics. Recycling, therefore, is key to reducing plastic pollution and fossil fuel emissions this century. Conventional recycling methods mechanically break down polymers into powders, burn them or use bacterial enzymes to dissolve them. The goal is to end up with smaller pieces that can be used for something else. Think shoes made from recycled rubber tires or clothing made from recycled plastic water bottles. It's not the same material anymore, but it doesn’t end up in a landfill or the ocean. But what if you could rebuild a new item from the same material? What if recycling didn't just offer a second life to plastics, but a repeat experience? That's exactly what Zhang and his colleagues have accomplished: They reversed a chemical method and discovered they can both break and form new chemical bonds in a particularly high-performance polymer. The PCN film directly peeled off from the glass substrate shows high transparency and flexibility. Source: Zepeng Lei "This chemistry can also be dynamic, can be reversible, and that bond can be reformed," said Zhang. "We are thinking about a different way to form the same backbone, just from different starting points." They do this by breaking the polymer –"poly" meaning "many"– back into singular monomers, its molecules, a concept of reversible or dynamic chemistry. What's especially novel about this latest method is that it has not only created a new class of polymer material that, like Legos, are easy to build, break apart and rebuild over and over, but the method can be applied to existing, especially hard-to-recycle polymers. These new chemical methods are also ready for commercialization and can plug and play with current industrial production."It can really benefit future design and development of plastics to not only create new polymers, but it's also very important to know how to convert, upcycle and recycle older polymers," said Zhang. "By using our new approach, we can prepare many new materials—some of which could have similar properties to the plastics in our daily life." This advance in the closed-loop recycling of plastics is inspired by the natural world, as plants, animals and human beings alike are currently part of a planetary-level, circular system of recycling, said Zhang. "Why can't we make our materials the same way?" Quelle University of Colorado Boulder More Science

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  • Silicone sponge captures unknown bacteria

    KIT Researchers Develop a Chip that Captures Microbial Dark Matter in Air, Water, and Soil – New Tool for Biotechnology and Medicine Copyright: RossHelen 23.01.2023 From human intestines to the bottom of the sea: Microorganisms populate nearly any habitat, no matter how hostile it is. Their great variety of survival strategies is of huge potential in biotechnology. Most of these organisms, however, are unknown, because they cannot be cultivated. To make better use of this "microbial dark matter", a team of researchers from Karlsruhe Institute of Technology (KIT) has now developed a "sponge" made of porous, formable silicone. Embedded in a chip, the material sucks up microorganisms in the surroundings, which can then be applied for further research. The findings are published in ACS – Applied Material and Interfaces . "It is quite surprising that nobody ever thought of using medical silicone for the settlement of bacteria," says Christof Niemeyer, Professor for Chemical Biology at KIT’s Institute for Biological Interfaces-1. Advantages are obvious, he points out. The special polymer used for e.g. breast implants does not interact with its environment. It can be modified easily, is long-lived and inexpensive. Niemeyer and his team came across it by chance. The results surpassed their expectations, the chemist says. "The material can take up microorganisms from the environment, no matter how moist or dry it is. For this purpose, the silicone had to be processed to a porous, sponge-like structure," he explains. The sponge-like structure of the chip (in gray) was produced with salt crystals. In the lab, it is colonized by the red microorganisms within a few days. Copyright: Institute for Biological Interfaces-1, KIT "Capture" of very different bacteria Experiments revealed that this silicone sponge captures a very large range of microorganisms in its holes. In the dry air of a poultry farm, the team identified Actinobacteriota species. These microorganisms are needed for the production of antibiotics. Moreover, they can be applied to produce substances to treat certain cancer diseases. "With the sponge, we can catch new bacteria that might benefit biomedicine," Niemeyer thinks. Something similar happened when the silicone sponge was immersed into a pool to cultivate pikeperch. Researchers found many bacteria belonging to the Candidate phyla radiation group, far more than in conventional, commercially available material. "These microorganisms account for about 70 percent of the microbial dark matter, as they have not been cultivable so far," Professor Anne-Kristin Kaster explains. With her team at the KIT Institute for Biological Interfaces-5, she analyzed the captured microorganisms using latest sequencing technology. Silicone sponge produced with table salt The team also proved that the sponge can enrich selected bacteria, if it is prepared accordingly. For instance, microorganisms processing glyphosate were "lured" into the sponge using this pesticide. And in contact with soil samples, the porous material was colonized by microbes within a few days. To make medical silicone habitable for microorganisms, the researchers had to process the material in a new way. The team added table salt to the polymer, which was dissolved again afterwards. As a result, small holes connected by small passageways developed. The desired sponge-like structure was obtained. For applications, the researchers then formed a "chip." This small unit consists of the same silicone as the sponge, but in its homogeneous rather than porous form. "The silicone chip, that is the combination of sponge and chip, can be produced easily with standard methods in nearly any size and number," Niemeyer says. "The robust research tool obtained can be used in nearly any environment. There is every indication that this chip is highly suited for the systematic investigation of microbial dark matter. It opens up interesting options for the cultivation of microorganisms that could not be cultivated so far." The main authors have filed a patent application for the silicone chip. Original Publication Ahmed E. Zoheir, Laura Meisch, Marta Velaz Martín, Christoph Bickmann, Alexei Kiselev, Florian Lenk, Anne-Kristin Kaster, Kersten S. Rabe, und Christof M. Niemeyer: Macroporous Silicone Chips for Decoding Microbial Dark Matter in Environmental Microbiomes. ACS Applied Materials & Interfaces, 2022. DOI: 10.1021/acsami.2c15470 Quelle Karlsruhe Institute of Technology (KIT) More Science

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  • Product development in Alpla's One-Stop Shop

    Interview with Norman Häusler, Director Corporate Product Development, ALPLA Werke Alwin Lehner GmbH & Co KG Exclusively for K-MAG Copyright: ALPLA 02.08.2022 Those who work meticulously to design a product can hardly await the day they can hold the finished item in their hands. Alpla is a company headquartered in Hard, Austria, that speeds up this process. Customers can convert their ideas into reality and ideally leave Alpla's STUDIOa with a prototype in hand. In this K-MAG interview, Norman Häusler describes the technologies that are part of this process and explains the product development process. Mr. Häusler, what prompted your company to create the STUDIOa product development space? Norman Häusler. Copyright: ALPLA Norman Häusler: When it comes to product development, we have been at our customers' side for decades from the first design draft and a prototype to the finished product. Aside from our technical know-how, customers can rely on our extensive experience in design. With the STUDIOa we have created an innovative space that focuses on this design aspect and enables us to collaborate with our customers to develop sustainable plastic packaging solutions with a custom design effectively and in a short time. What are the technologies your customers can utilize for product development at STUDIOa? Häusler: The objective of a workshop is to give customers a realistic idea of ​​the packaging at the point of sale and ideally send them home with a finished sample. To do this, we implement various methods from our modeling and simulation department, for example, and combine it with computer-assisted media such as virtual and augmented reality. We also feature a powerful 3D printer on location to assist in this endeavor. How is new product development implemented in the STUDIO? Häusler: Product development primarily focuses on the close collaboration between cross-functional teams on the customer side and on our side. It's important to bring the experts from a variety of disciplines such as development, production, toolmaking, the filling lines, or marketing together and encourage decision making. This facilitates fast feedback loops to boost the development process. We offer a wide variety of packaging solutions, from the first design draft to the finished product. Virtual reality allows customers to experience the designed products even more realistically. Copyright: ALPLA What feedback are you getting from your customers? Häusler: Our customers have been very supportive of our new concept. We received very positive feedback during the launch and the first workshops we hosted. This is also reflected in increased appointment requests. Or to put it another way: STUDIOa is already very well booked! How does Alpla plan to drive changes in the plastics industry in the future? Häusler: Since the founding of our company in 1955, innovation has been part of our corporate DNA. This means understanding the market and its constantly changing requirements. Speed to market has always been and still is a key aspect of what we do. We also emphasize the development of sustainable packaging, which includes material savings, recycling rate increases, or the design of ideal recyclable packaging. It is important to remember that only the perfect combination of aesthetics and functionality makes the difference at the point of sale. Kyra Molinari (Editorial team K-MAG) More Science

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  • BASF and THOR GmbH fight fire together

    Copyright: ABBPhoto 03.08.2022 BASF and THOR GmbH are combining their expertise in non-halogenated flame retardant additives to provide customers with a comprehensive solution that will enhance the sustainability and performance for specific plastic compounds, as well as meet stringent fire safety requirements. Flame retardancy is an essential element for plastic components or composites which are commonly used in transportation, construction, household, and industrial applications, as accidental heat and flame exposure can lead to serious damage and endanger lives. The growing demand from the global construction and automotive industry combined with stricter fire safety standards will significantly influence demand for sustainable flame retardant chemicals. Combined expertise in flame retardant additives provides customers and end-users with information highlighting the synergistic benefits of BASF's halogen-free flame retardant Flamestab® with THOR's phosphonates AFLAMMIT® technologies. Source: BASF The experts at THOR and in plastic additives at BASF have collaborated for many years in developing sophisticated solutions to meet the demanding flame retardant specifications focusing on alternatives to halogen containing additives. Both parties are active members of the Phosphorus, Inorganic and Nitrogen Flame Retardants Association PINFA and work closely to deliver sustainable polymeric systems that withstand ignition and fire propagation during their service life. The combined expertise in flame retardant additives provides customers and end-users with information highlighting the synergistic benefits of BASF’s halogen-free flame retardant Flamestab ® with THOR’s phosphonates AFLAMMIT ® technologies, for polyolefins which is typically a challenging flame resistance application. "A thorough and multidimensional assessment of an additive solution is essential to shorten the time to market. The closer our suggested formulations are to the requirements of the end-users, the shorter the development time and costs for our customers. At THOR, we work continuously on improving our flame retardants and their performance in the desired plastics compounds. Depending on the market needs, a huge variety of fire safety standards are available for testing our own developed flame retardant formulations. As a service, our project partners, such as BASF, provide us with newly formulated plastics films, molded or extruded specimens for evaluation of performance," explains Armin Eckert, BU-Head of Performance Chemicals, THOR GmbH. "Providing superior fire safety to a plastic part while maintaining other characteristics such as mechanical performance and light stability is a real challenge," explains Dr. Achim Sties, Senior Vice President, Performance Chemicals Europe, BASF. "BASF technical experts are hard at work to provide solutions to meet our customers' requirements and leverage our strong experience and network to respond with cost effective and sustainable technological solutions. Together with THOR, we focus on technical combinations that help shorten the journey for a formulator or a converter to reach their flame retardancy target and progress efficiently towards certification in a complex norm and testing environment." Source BASF SE THOR GmbH More Science

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  • Powered-up plastics

    Source: StudioPeace 08.12.2022 Until now, it has not been possible to additively manufacture sensors and other electronic devices in a single operation. However, a research team from the Fraunhofer Institute for Manufacturing Engineering and Automation IPA has now succeeded in doing just that. The key to this achievement? Conductive plastics. In the "Electronic functional integration in additively manufactured components" research project, researchers from the Center for Additive Manufacturing Technologies at Fraunhofer IPA have succeeded in using a 3D printer to produce inductive proximity sensors in any shape, although the printing process had to be repeatedly interrupted in order to lay the conductor tracks in the housing. Consequently, in the second phase of the project, Stefan Pfeffer’s research team joined forces with plastics processing machinery manufacturer Arburg to investigate which conductive plastics could be used instead of silver or copper. To this end, the researchers experimented with various thermoplastic elastomers (TPE). These are flexible plastics that can be processed when heated. TPEs are conductive if, for example, they contain a sufficient amount of carbon black particles. First, the research team looked for the TPE with the lowest electrical resistance, since the lower the resistance, the greater the number of potential applications there are. Endurance testing thermoplastic elastomers Resistance measurement on a thermoplastic elastomer with carbon black particles: The lower the resistance, the more potential applications there are. Source: Fraunhofer IPA/Photo: Stefan Pfeffer Pfeffer and his team then subjected the selected material to an extensive series of material tests: They exposed it to heat and cold to test how the electrical resistance changed. They passed current through it at increasingly higher voltages until the conductive paths burned through. They stretched the TPE to find out to what point it would return to its original shape and how the conductivity would gradually decrease under tension. They artificially aged the material to see how that affected conductivity and they exposed it to the elements on a flat roof for a year to find out how the TPE weathers and how its properties change during this process. The research also focused on the question of what settings need to be made on the "freeformer," Arburg's industrial additive manufacturing system, to minimize the material’s electrical resistance and to test whether the print orientation (horizontal or vertical) affects the conductivity of the printed components. Sensors and orthoses are possible fields of application The question of how best to install electronic components and make contact with the printed TPE conductor path has now been resolved. Source: Fraunhofer IPA/Foto: To serve its purpose, the conductive TPE must be embedded in another thermoplastic with insulating properties during printing. The crux of the matter is that the two plastics need to bond – ideally, it should not be possible to separate them afterwards – but they must not smear during the printing process either. Otherwise, without a clear separation between conductive and insulating materials, there is a real likelihood of triggering a short circuit. Pfeffer's research team also resolved the question of how electronic components such as LEDs, resistors or microcontrollers can best be installed to enable contact with the printed TPE conductor track. LED demonstrator with integrated circuit board, printed TPE track, contacted LED and insulating PBT housing. Source: Fraunhofer IPA/Foto: Rainer Bez "Conductor tracks made of carbon black-based TPE are inexpensive to produce," says Pfeffer, "but they will not be able to replace soldered conductor tracks because of their poorer overall conductivity." Despite this, there are still a number of interesting areas of application. For example, capacitive sensors such as touch switches or level gauges are potential options, with heating mats or orthoses that release heat at certain points on the body to support healing offering further possibilities. "You could also equip the suction pads of robots with conductor tracks made of TPE in order to monitor wear and tear on the material. The higher the resistance, the more worn the gripper." Quelle Fraunhofer Institute for Manufacturing Engineering and Automation IPA More Science

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