To this end, the partners have launched the HyEnd-Wood project (Hybridised Engineered Wood - development of a hybridised wood-based material for structural components by forming a strand-based composite semi-finished product). The good specific mechanical properties of the base material wood are to be utilised to create innovative and "green" structural materials using strands. The material properties of the final material are to be specifically adjusted to the application through possible hybridisation.
The aim of the HyEnd-Wood project is to develop and evaluate a wood-based material with at least 60% wood content and the associated manufacturing process for structural components in the automotive sector. A technology demonstrator that is at least weight-neutral is to be realised with the same or higher functionality compared to a reference assembly. TRL 6 is to be achieved for a wood-based bulk moulding compound (BMC) and/or sheet moulding compound (SMC) and the associated processes.
Using strands (load-bearing), chips (filler), additives (fire protection, etc.) and an adhesive system, a "green" and free-formable structural material is being developed that can be processed in a two-stage process, based on the familiar BMC and SMC processes from the CFRP and GFRP sectors, first into a semi-finished product and then into a near-net-shape component. This is intended to close the gap in lightweight construction between freely mouldable but non-load-bearing WPC and load-bearing but not freely mouldable moulded wood.
Wood protection concepts are to be considered through powder in-mould coating (PiMC) or through the addition of additives.
The simulation of the material for load flow-compliant design and thus resource conservation is also part of the project.
Hybridisation with conventional materials, such as steel, aluminium or plastics, should take place where it appears necessary and sensible. Examples of this include the moulding and recasting of local reinforcements or joints.
The development of a wood-based structural material should therefore expand the portfolio of green lightweight materials and thus defuse the tension between modern lightweight materials (such as CFRP) and social and legal emission requirements. Sustainability is to be further strengthened through the use of domestic beech wood and by considering the cascading utilisation of waste and residual wood.
Mitras Composites Systems GmbH, the Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI, the Department of Separating and Joining Manufacturing Processes at the University of Kassel and the Institute of Vehicle Concepts at the German Aerospace Centre (project management) are working on the above-mentioned technological developments as partners in the project. They are actively supported by the associated partners Volkswagen AG and Jowat SE.