Fraunhofer Institute for Surface Engineering and Thin Films IST
Fraunhofer Institute for Surface Engineering and Thin Films IST
Aluminium Druckgusssensor
© Fraunhofer IST, Elke Bürger

The Fraunhofer IST at the EUROGUSS 2026

Information material on innovative casting processes, including sensor technology and surface treatment in die casting, as well as life cycle assessment.

© Fraunhofer IST, Elke Bürger

Compilation of information material for EUROGUSS 2026

Fraunhofer IST at the EUROGUSS 2026

The topics presented by Fraunhofer IST adress innovative casting processes and will include sensor technology and surface treatment in die casting, as well as life cycle assessment. 

Fraunhofer IST will be represented at the exhibition at a joint booth togehter with Fraunhofer IFAM. In addition, a session will be hosted by Rowena Duckstein (Fraunhofer IST) and Christoph Pille (Fraunhofer IFAM), offering deeper insights into the research activities of both institutes. 

 

Exhibition:

You can find us at booth 4A-233 in the exhibition.

 

Session:

Wednesday, January 14, 2026, 10:00–10:30 a.m.

fusionCASTING – Insights into new Fraunhofer concepts for composite casting of aluminum sheets and profiles in die casting

Rowena Duckstein¹, Christoph Pille²

¹ Fraunhofer IST
² Fraunhofer IFAM

Success factor surface - surface technology for sustainable products and systems

At the Fraunhofer Institute for Surface Engineering and Thin Films IST we open up the potentials for future-oriented products and the associated competitive and scalable production systems. Our research encompasses plant engineering, entire process chains of process engineering, process technology and manufacturing technology all the way through to the consideration of entire factories. Taking the requirements of sustainability as a starting point, we maintain an overview of the entire product life cycle – from the material, through the process of creating the component and product, and on to recycling.

Based on our technology and competence fields, the technical departments of the Fraunhofer IST create solutions especially for the sectors plant and mechanical engineering, tools, vehicle construction, aerospace, energy, optics, medical and pharmaceutical process engineering, agricultural and food industry, as well as environmental technology. this includes solutions for battery production, the establishment of hydrogen technologies and the production of tribological, sensory and precision optical systems, methods and technologies in the areas of analytics, simulation and digital services as well as the systematic consideration of sustainability requirements and a circular economy using life cycle engineering.

Flagship project: FutureCarProduction

Holistic solutions for sustainable vehicle construction

The automotive industry is currently experiencing the biggest transformation in its history to date. The transition to electromobility is viewed as an important building block on the path towards achieving climate-neutral mobility by 2050 at the latest, as envisaged in the EU’s “Zero Pollution Action” plan. Until now, around 80% of CO2 emissions had resulted from exhaust gases during the service-life phase. With electromobility, however, the CO2 hotspot is shifting from the service-life phase to the production phase. In addition to the battery, the focus is now also on the car body – the second-largest generator of emissions – in order to achieve ecological sustainability. It is expected that in the future, proof of sustainability – in addition to technical performance and costs – will become a decisive success factor for new car-body concepts.

The consortium of the flagship project “FutureCarProduction” is developing holistic solution approaches for the evaluation of new car-body concepts in the automotive industry. This entails the establishment of methods, processes and technologies with which ecological sustainability can be methodically evaluated and technologically guaranteed – particularly in areas where a conflict of objectives with technical performance and costs may arise.

FutureCarProduction is thereby also responding to Tesla’s innovative gigacasting concept, which challenges the worldwide-established design and production methods for car-body construction. In this new construction method, highly integrated large castings are cast in one piece from aluminum; these replace entire body segments that were previously assembled using numerous individual sheets and components. In its approach to a holistic sustainability assessment, the Fraunhofer consortium is also taking into account optimizations in material and product quality, repair capability and crash safety.

For further information about the project, please click on the link below.
Modern Silver Automobile Body Production Line and Robotic Arm in Factory. Ai Generated Images
© adobe.stock.com, udin
The aim of the “FutureCarProduction” project is the investigation and holistic evaluation of the effects of secondary materials on car-body construction methods.
A worker wearing protective gloves holds a soldering pot over a tool on a machine. Molten metal flows from the pot into the mold below. Additional tools and a work area are visible on the workbench.
© Fraunhofer IGCV
One example is the testing of the properties of casting alloys. In addition to this, various innovative casting, forming and joining processes are being investigated.
A round metal block lies on a table. The block has four raised dots that form a pattern. Next to the block is a metal tool with a long handle and a pointed edge. The table has a label that reads “AL BASIS.”
© Fraunhofer IGCV, Tobias Hase
The main focus of the investigations is directed towards the use of secondary materials – THE lever for sustainable vehicle construction.

“fusionCASTING” – Casting technique combining die casting with aluminum sheets and profiles for large body structures

As part of the FutureCarProduction flagship project, the innovative fusionCASTING manufacturing technology is being investigated as a key approach to producing large-format aluminum car body structures efficiently, sustainably, and with high crash performance. Learn more about fusionCASTING below.

 

© adobe.stock.com, Vadym

“fusionCASTING”

Casting technique combining die casting with aluminum sheets and profiles for large body structures

Further information

Our solutions in the field of sensor technology

The measurement of force, pressure, temperature, wear and other variables directly in main load zones or on tool active surfaces provides valuable data by means of thin-film sensor technology in order to optimize existing production processes or simulation models. The application of wear-resistant and tribologically adapted thin-film sensors enables measurements in areas which were previously difficult to access.

 

© Fraunhofer IST, Manuela Lingnau

Expertise

Sensor technology

Sensor technology
 

© Fraunhofer WKI, Manuela Lingnau

Project sheet

Thin-film systems for temperature measurement in die-cast aluminium

Thin film systems
 

© Fraunhofer IST

Reference project

Multi-sensory tools for cold forming

MuWeKa

Our solutions in the field of tribology

Friction, wear and corrosion cause costs amounting to billions of euros every year in Germany alone. The development of durable, high-performance and resistant tribological systems with the aid of surface refinements is a key factor in saving costs and reducing environmental pollution therefore forms a focus at the Fraunhofer IST. Furthermore, thin, highly resilient sensor layers enable the targeted monitoring of such tribosystems, thereby reducing the risk of failure and, consequently, protecting people and the environment.

 

© Fraunhofer IST, Rainer and Natalie Meier

Technologies

Tribology

Tribology
 

© Fraunhofer IST

Tribology

Coatings for aluminum and magnesium die-casting tools

Al and Mg die-casting tools
 

© Fraunhofer IST

Chemical, mechanical and thermal surface treatment

Functional configuration of the surface topography of components and tools

Surface topography

Our solutions in the field electroplating and wet-chemical processes

If a coating is intended to improve the properties of a base material, add new properties or protect the surface, electroplating plays a key role in many sectors as an effective and cost-efficient process. With the establishment of cyber-physical production systems for the entire process chain, spanning everything from cleaning, pretreatment and coating all the way through to surface analysis, the experts at the Fraunhofer IST are facilitating the exploration of new fields for applied research.

 

© Fraunhofer IST

Technologies

Electrochemical processes

Electrochemical processes
 

© Fraunhofer IST

Electrochemical processes

Digitization of electroplating production processes

Digitization
 

© Fraunhofer IST, Falko Oldenburg

Additive manufacturing for aerospace

Surface technology for the generative production of polymer components

AM for aerospace

Our solutions in the field of sustainability strategy, management and Life Cycle Engineering

Fraunhofer IST offers customized solutions for promoting circular economy for companies across various sectors. This includes the development of new technologies and business models that enable high-quality recycling. Furthermore, the institute specializes in developing analytical tools for assessing environmental impacts and supports companies in obtaining external sustainability certificates for their products and processes. Through sustainability assessments, Life Cycle Engineering approaches, and cost-efficient solutions, Fraunhofer IST contributes to the establishment of closed material cycles.

 

© Generative ART - stock.adobe.com

Strategically manage sustainability

Sustainability management

Spot sustainability opportunities early, measure impact, and embed it successfully into your strategy.

Sustainability management
 

© Teerasan - stock.adobe.com

Optimize CO₂ footprint and environmental performance across the product lifecycle

Life Cycle Engineering

Leverage methods and tools to track, analyze, and enhance the sustainability of products and companies.

Life Cycle Engineering
 

At the Fraunhofer IST we develop tools and instruments for measuring sustainability performance. Within the framework of Life Cycle Engineering we take into account the entire product life-cycle – from raw material to recycling. With our customers and partners we are thus working together on a path to climate neutrality.

To the Video

Jobs and career at the Fraunhofer IST

Just as diverse as our research fields are the opportunities for your career at the Fraunhofer IST: Whether in training, as a student assistant, in the final thesis or doctorate, as a scientist, in IT, technology or in the administration – become part of the team!

 

© Fraunhofer IST

Jobs and career

Become part of the team!

 

© Fraunhofer IST

Annual report 2024

Annual report 2024

Stay informed

 

© Fraunhofer IST, Falko Oldenburg

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