Metal components in drives are stable and durable, but are complex to manufacture and heavy, which leads to higher energy consumption in the application. Plastic components offer a lighter and often more energy-saving alternative, but must be made wear-resistant using reinforcing materials such as glass fibers. However, this reinforcement makes recycling considerably more difficult, as separating the materials is expensive and often impractical.

As part of the BMBF funding measure “Biologization of Technology: Bioinspired materials research”, the Fraunhofer Institute for Mechanics of Materials IWM, together with Basell Polyolefine GmbH and 2RPS Mechatronik GmbH, is investigating how so-called all-hydrocarbon composites (all-HC) can be optimized for use in drive components. Their behavior under tribological load, i.e. in frictional contact, is based on biologically inspired principles: Similar to how bone tissue grows adaptively under load, these polyethylene composites develop fiber-like structures due to frictional heat and sliding motion, which strengthen the components and increase their wear resistance.

A central aim of the project is to use the adaptive structures efficiently both in operation and during processing. This property, combined with the possibility of using environmentally friendly lubricants, makes the all-HC composites a forward-looking alternative for mechanical engineering. Thanks to their recyclability and durability, they could reduce dependence on conventional materials and significantly reduce the environmental impact.

Further information on this innovative project can be found on the website (only in German), where background information and contact details are provided.