en.Wedoany.com Report on Mar 27th, Fraunhofer Institute for Microstructure of Materials and Systems (IMWS) in Halle (Saale), Germany, has introduced a surface functionalization technology that directly regulates the performance of plastic components through micro- and nanostructures, eliminating the need for additives or coatings, thereby enhancing recycling efficiency and reducing costs. This surface functionalization technology can be widely applied in industries such as automotive, medical, and packaging, achieving customized requirements such as specific adhesion, wettability, or optical properties.

As the core of the surface functionalization technology, IMWS has developed a cross-scale simulation tool called "3-ScaleSim," based on the mesh-free Meshfree software from Fraunhofer ITWM, which for the first time enables full-process simulation of the injection molding process. This tool connects macro-, micro-, and nanoscale designs, integrating material data and process parameters such as pressure and temperature through digital twins. A nano-micro-macro database and experimental validation ensure model optimization, replacing feasibility studies with virtual testing, enabling early evaluation of micro- and nanostructures, precise prediction of surface properties, and shortening development time. The Meshfree software has been extended to the micro- and nanoscale and was awarded the 2024 Joseph Fraunhofer Prize.

This surface functionalization technology is particularly beneficial for small and medium-sized enterprises (SMEs). Plastic processors can use the full-process demonstrator to digitally test tool designs, polymers, and process variants before investing, reducing costs and risks. Researchers point out that this accelerates development cycles and decision-making speed, addressing the challenges of resource conservation, recycling, and functional requirements in the plastics industry.