Fraunhofer IWU develops automated cable and fiber laying for industrial applications

With “Automated Cable Assembly” (AuCA) and Fiber Encapsulating Additive Manufacturing (FEAM) technology, the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) has developed two processes that could optimize the production of components with integrated cabling and fiber technology. Both technologies make it possible to embed cables or fiber optic tracks directly into a component, which considerably simplifies and accelerates the production of components with complex cabling, sensors or light modules.

AuCA technology allows flexible cables to be laid directly onto the component without having to be gripped and positioned by robots, as was previously the case. Instead, the cable is pulled from an endless reservoir and placed and fastened with pinpoint accuracy using a special tool head. This process replaces many manual work steps in the automotive industry, where cable harnesses often comprise several kilometers of cable and are laid manually.

In parallel to AuCA, Fraunhofer IWU is developing FEAM technology, which enables the direct integration of fiber optic cables. A glass fiber or a fiber bundle is applied to the component using a polymer coating. This allows data cables and lighting elements to be integrated flexibly and over a large area. This opens up a wide range of applications, from fast data transmission to the production of lightweight, flat lighting elements. A prototype of the print head for the FEAM technology already achieves deposition speeds of up to 50 mm/s with fiber thicknesses of 0.2 to 1 mm and enables simple fixation of the glass fibers without special requirements for the cladding material.

By presenting the AuCA and FEAM technology at Formnext 2024, Fraunhofer IWU aims to demonstrate the potential for automated cable and fiber laying in various industries. Applications can be found in the automotive industry as well as in electronics and lighting technology. The technologies enable efficient production and could lead to significant cost savings, especially for complex components with integrated cabling.