Climate-friendly production, inspired by nature

Joint project BioFusion 4.0

Climate-friendly production, inspired by nature

Joint project BioFusion 4.0

Global challenges such as resource scarcity and climate change demand a mindset shift in the industry. In BioFusion 4.0, partners from industry and science research sustainable products and production processes under the leadership of the Fraunhofer Institute for Production Systems and Design Technology (IPK). Utilizing the concept of biological transformation, they apply biological principles to industrial applications. 

A promising approach of BioFusion 4.0 is the smart recycling of valuable materials in order to process them into raw materials for additive manufacturing. Human-centered assistance systems for workers lead to more ergonomic production processes, while biogenic and biodegradable polymers open up new application fields for plastics. Until 2024, the partners plan to develop solutions for the sectors mechanical and plant engineering, waste disposal, energy generation, drive technology, electromobility, and vehicle construction.

Trials at the Werner-von-Siemens Centre for Industry and Science (WvSC), the Mercedes-Benz Plant Berlin, and other project partners show what a successful practical implementation might look like. For example, the developed applications are put to the test in the assembly of power control units for battery electric vehicles. The consortium partners will set up a technology demonstrator to illustrate and quantify the benefits of the research results.

The CONTACT Elements for IoT platform records the CO2 emissions along all logistics and production steps in the Digital Twin of the production line. This allows operators to fulfill upcoming legislative obligations. Additionally, optimization potential is revealed by comparing the actual and the expected emissions. Thereby, the digital twin contributes to a more energy-efficient production. CONTACT Software uses the project results to develop industry solutions that enable companies to operate in a more resource- and climate-friendly way.

The consortium

Fraunhofer IPK (consortium leader), Werner-von-Siemens Centre for Industry and Science, Mercedes-Benz AG, Technische Universität Berlin, CONTACT Software, and eight other industry, technology, and associated partners 


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