03.02.2025
International
Fraunhofer Institutes for Machine Tools and Forming Technology IWU and for Manufacturing Technology and Advanced Materials Research IFAM have made a breakthrough in materials research. The composite material "Hoverlight" sets new standards for the construction of machine tools.
Hoverlight is a composite of metal foam and hollow spheres and can serve as the core of sandwich structures. This sandwich principle results in a significant weight reduction, and the Hoverlight core guarantees high damping: the aluminum foam with the integrated hollow spheres dampens vibrations significantly more than previously used composite materials, leading to higher precision in machining and a longer lifetime of the machine. The sandwich construction also enables significant weight savings, allowing for higher dynamics in machining processes. Hoverlight adapts to the specific requirements of different applications.
Successful application in practice
In a joint project with Chiron Group SE, HoverLIGHT has been working effectively in the crossbeam of a milling machine. According to Fraunhofer, a weight reduction of 20 per cent was achieved: The Hoverlight crossbeam is significantly lighter than a comparable assembly made of conventional materials. Moreover, vibration damping increases by a factor of 3, leading to higher precision and longer tool life. Finally, Fraunhofer reports that machines equipped with Hoverlight crossbeams can produce more parts in less time thanks to higher speed and precision.
Dr.-Ing. Jörg Hohlfeld, responsible for the research area of metal foam at Fraunhofer IWU: "With HoverLIGHT, we have developed a material that pushes the boundaries of what is possible in vibration damping. We solve the conflict of objectives that arises from the inherently contradictory requirements of a stiff design of modern machine tools, lightweight moving assemblies, and effective vibration damping."
Next goal: attractive manufacturing costs
All moving components in machine tools, such as machine slides, are predestined for HoverLIGHT. However, numerous other applications are also conceivable outside mechanical engineering, wherever lightness, stiffness, and precision matter.
The researchers are continuously working to improve HoverLIGHT and expand its range of applications. The goal is to adapt the properties of the composite material to the requirements of further applications and to reduce its manufacturing costs through industrialized processes. The production of hollow spheres is complex, energy-intensive, and not yet reproducible. A promising approach is to use simpler and thus cheaper to produce metallic blisters instead of hollow spheres, as in drug packaging. The Fraunhofer team is confident this should allow for significant cost reductions within a few years.
The German Federal Ministry for Economic Affairs and Climate Action funded the project partners (Fraunhofer Institutes IWU and IFAM, along with Chiron SE) through the IGF (Industrial Joint Research) program, a government initiative designed to support pre-competitive research. This funding follows a decision by the German Bundestag. The VDW Research Institute offered technical and organizational support to the project partners throughout the initiative.
Featured photo: Fraunhofer IWU