Lightweight design and Composite Technologies

School of Engineering and Environment

We answer questions regarding the mechanical behaviour of polymers and composites using a range of appropriate experimental and numerical methods.

Lightweight construction and fibre composite technologies are key technologies for a climate-neutral industry and sustainable mobility. Together with industry and research partners, FHNW develops innovative, resource-efficient and circular material, process and digitalisation solutions along the entire value chain of fibre composite structures — from material development, manufacturing and simulation through to testing, structural health monitoring, repair and recycling.

Our vision is to achieve the industrial breakthrough of Swiss-made sustainable fibre composite and lightweight construction technologies for a climate-neutral economy by 2050. The focus is on high-performance yet sustainable composite materials that meet the highest requirements in terms of structural performance, safety, functionalisation and resource efficiency.

FHNW combines experimental and numerical methods to develop the next generation of composite materials and lightweight structures. These include thermoplastic and thermoset composites, bio-based and recycled materials, self-reinforced polymer composites, multifunctional materials, and smart structures with integrated sensors and structural health monitoring (SHM).

The Composite Materials Laboratory (link here) offers comprehensive infrastructure and expertise along the entire process chain. This includes:

Processing technologies for thermoplastic and thermoset composites
Additive and robot-assisted manufacturing processes
TFP, tape laying, consolidation and forming processes
RTM, infusion and autoclave processes
Welding and joining technologies for thermoplastic composites
Process simulation, material modelling and digital process chains
Inline monitoring and data-driven process analysis

This is complemented by state-of-the-art testing and analysis methods for material, structural and process characterisation:

Mechanical testing under static, dynamic and cyclic loads
Impact, CAI and fatigue testing
FST characterisation
Ultrasonic and imaging-based non-destructive testing methods
Microscopy, surface and damage analysis
Thermal, rheological and chemical analysis
Digital image correlation (DIC) and sensor-integrated testing methods

A particular focus lies on the industrial implementation of sustainable technologies for aviation, mobility, energy, infrastructure, sports, mechanical engineering and industrial applications. The research activities address, among other topics:

Circular composite solutions and recycling strategies
Bio-based and CO₂-reduced matrix systems
Lightweight construction for energy-efficient mobility and hydrogen applications
Automated high-rate manufacturing
Digital twins and simulation-based development
Smart composite structures with integrated sensors
Repair and life-cycle engineering

Through close collaboration with industry, start-ups, networks and international research partners, FHNW enables the direct transfer of research results into industrial applications and supports companies in developing market-ready, sustainable and future-proof lightweight construction solutions.

Selected Projects

LiteWWeight®: An innovative multi-material joining technology for sandwich materials

The new technology has reached industrial maturity thanks to the collaboration between MultiMaterial-Welding AG and the Institute of Polymer Engineering at FHNW.

Institute: Institute of Polymer Engineering

Taking waste from the aviation industry to new heights

Researchers at the FHNW have developed a cost-effective and sustainable sole made of recycled carbon fibres for a running shoe by the Swiss sports brand On.

Institute: Institute of Polymer Engineering

High Performance Composite Structures for high temperature loads

Development of sustainable and cost-effective fiber composites with demanding temperature and fire resistance.

Institute: Institute of Polymer Engineering
Research field: Materials, Aerospace

Next generation of composite manufacturing using digitalization

To optimize the production of composite materials, FHNW researchers have succeeded in enabling cyber-physical systems to monitor and transfer real production conditions to virtual environments.

Institute: Institute of Polymer Engineering
Research field: Materials

Additive Fusion Technology for 3D printed CFRP parts

The traditional production of CFRP components is very time-consuming and expensive. The Swiss start-up 9T Labs has therefore developed a new method with which composite parts can be produced in large numbers using 3D printing and post-consolidation.

Institute: Institute of Polymer Engineering
Research field: Materials

Robot-Assisted Additive Manufacturing

Robot-assisted additive manufacturing is a relatively novel but promising technology for economically producing even larger plastic components.

Institute: Institute of Polymer Engineering
Research field: Materials

Digital Twins for Non-Destructive Evaluation of Composite Materials with Ultrasound

An innovative new method for non-destructive ultrasonic testing of laminated composite materials.

Institute: Institute of Polymer Engineering
Research field: Materials

Development and Optimization of Thermoplastic Winding Technology for Manufacturing of Cryogenic Hydrogen Tanks

Hydrogen plays a central role as an energy storage and carrier in the ongoing energy transition. The aim of the project is to develop a cost-effective, high-strength, lightweight hydrogen tank made of fiber composites that has been specially developed for transporting liquid hydrogen.

Institute: Institute of Polymer Engineering
Research field: Materials

SuMa - Sustainable materials for 3D printed composite parts

High-performance composites exhibit excellent mechanical and chemical Howev-er, the comparably high costs and the negative climate balance, especially for car-bon fiber composite parts, are critical and will be even more important in future applications. The project SuMa focuses on product development of sustainable composite materials for 3D printing.

Institute: Institute of Polymer Engineering
Research field: Materials

Sustainable fibre reinforced composites

Experimental and numerical analysis of drapability in flax fiber-based textiles

Institute: Institute of Polymer Engineering
Research field: Materials

Recywind - Recyled carbon fibre in structural application

We are excited to present a cutting-edge high performance and custom-built bicycle frame, made from recycled feedstock without deducting structural integrity.

Institute: Institute of Polymer Engineering
Research field: Materials

Thermoplastic Thin-Ply Tapes as a Key Technology for Lightweight Liquid Hydrogen Tanks

The use of hydrogen as an energy carrier plays a key role in the successful energy transition. For the safe and efficient transport of hydrogen, new materials are required that are both lightweight and high-strength while withstanding extreme temperatures. The research project LeiWaCo (Lightweight Hydrogen Container), in collaboration with the industrial partner Suprem SA and in association with the German BMBF research project of the same name, is developing innovative thermoplastic fiber-reinforced composites for use in cryogenic hydrogen tanks. The aim is to produce a lightweight, tight, and cost-efficient tank material that meets the stringent requirements of hydrogen mobility.

Institute: Institute of Polymer Engineering
Research field: Materials