The Institute of Structures and Design has set itself a major goal: to lighten the future. At our sites in Stuttgart and Augsburg, we develop high-performance structures for the aerospace, automotive engineering and energy technology sectors that go above and beyond the standards set by conventional developments and deliver real technological advances. Our work is based on the interplay between high-performance, temperature-resistant materials and the very latest digital technology. This combination allows us to develop new construction methods that open up previously unimagined possibilities in lightweight construction in the areas of assembly, system integration and recycling.
In our five departments and our close, strategic cooperation with the Institute of Materials Research, we push forward technical progress on a daily basis. From the materials we use through to the demonstrators we construct and the automated production processes we develop, we always rely on solutions that are climate friendly, efficient and conserve resources.
The thrust chamber as part of a rocket engine is one of the most highly stressed components. Therefore, it has a great influence on the performance, reliability and cost of a launcher system. The combination of modern composite materials with innovative design concepts and cooling methods within the framework of Black Engine technology promises advantages in terms of simplified production, reliability and reusability.
In September 2016, the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) and the Canadian University of British Columbia (UBC) launched the collaboration initiative DLR@UBC.
As a spin-off of the German Aerospace Center, msquare GmbH distributes, develops and produces innovative induction heating technologies. These can be used profitably and resource-saving in the manufacture and repair of fibre composites, for example in wind energy or aerospace
In the project „Procomp“ manufactured a thermoplastic carbon fiber reinforced inter-stage structure for next generation European launcher systems. Using a cutting edge flashlamp heatsource the DLR developers manufactured two scaled demonstrator of a lattice inter-stage structure using in-situ Automated Fiber Placement (AFP).
To see here: Scaled, intertank structure demonstrator (left untrimmed, right trimmed part)
Im Projekt „IRAS“ wird in Zusammenarbeit von Industrie und Forschung in Baden-Württemberg eine integrierte Entwicklungsplattform für kostengünstige Satelliten aufgebaut.
Hier zu sehen: Die Herstellung der trockenen Flechtstruktur eines CMC-Orbitaltriebwerks.
Thermoplastic composites, thermoplastic advanced fiber placement (T-AFP), in-situ consolidation (ISC), flashlamp heating, continuous ultrasonic welding (cUS), resistance welding (RW)
The project Urban Rescue deals with different rotorcraft configurations (helicopters and eVTOLs) which are necessary for urban rescue scenarios.
The newly developed Tailored Skin Single Duct (TSSD) design for wing or empennage leading edges significantly reduces production costs, especially of the microperforated outer skin. Furthermore, new possibilities for cleaning and maintenance are opened up by its complete dismantlability.