Re:light - recyclable lightweight technologies

The European aircraft industry is facing a profound dual structural transformation. On the one hand, production and value-added systems must be made more sustainable and resource-efficient; on the other hand, the growing shortage of skilled workers is driving the adoption of new forms of automation. This tension is giving rise to entirely new requirements for manufacturing process chains, structural design methods, and materials—particularly in the field of lightweight construction. This is precisely where the RE:LIGHT project comes in: It aims to specifically expand the existing research infrastructure at the PuK site in Stade to create a research- and industry-oriented foundation for human-centered, adaptive, and circular lightweight production in aircraft manufacturing.

A particular focus of the institute is on the development and investigation of systematically modified, recyclable material systems based on carbon fiber-reinforced thermoplastics (CFRT). The goal is to specifically design and evaluate innovative materials not only for primary manufacturing but also with regard to separability, reusability, and recyclability. The existing laboratory equipment will therefore be supplemented in RE:LIGHT with specific analysis and processing techniques that enable comprehensive materials characterization as well as the derivation of application-oriented material and process strategies.

To this end, the institute will have a total of €1.3 million from the European Regional Development Fund at its disposal over the next two and a half years. Among other things, the plan is to procure a high-performance twin-screw extruder specifically designed for processing fiber-reinforced high-performance thermoplastics. In addition, the laboratory equipment at the site—which has thus far focused on thermal and mechanical analyses—will be expanded to include further analytical capabilities. To this end, a scanning electron microscope (SEM) and an infrared spectrometer (IR) will be procured.