Ostseestaal shapes the future

Research and development

We invent what does not exist.
modern steel construction

Innovative Strength Ostseestaal

Research and development are key drivers of innovation in steel construction. As part of national and international research and funding projects, Ostseestaal GmbH & Co. KG develops forward-looking solutions for maritime steel construction, offshore applications and complex specialised structures.

Our aim is to develop technical innovations with a practical focus and to rapidly translate new technologies into commercially viable applications. In doing so, we combine our many years’ experience in steel construction with modern development and simulation methods.

Research and development projects

  • A passenger aeroplane against a clear blue sky with white clouds

    TACOMA-OS lightweight tools for cryogenic tanks

  • Technical feasibility study NIWAAM

  • Intelligent press for automated cold plastic forming

Development projects supported by EU funds

CONTRIBUTION TO THE R&D PROJECT
Title of the individual project applied for:

Technical feasibility study NIWAAM

Short title:

NIWAAM

Title of the joint project:

Additive manufacturing of complex moulds and tools made of 1.3912 for the production of components made of carbon fibre and glass fibre reinforced plastics (CFRP, GFRP)

The aim of the project was to develop a technology for the additive production of multi-dimensionally moulded structures made from the material FeNi36 (hereinafter referred to as 1.3912). The background to this is the search for a way to manufacture extremely cost-intensive milled components, which are used in the manufacture of laminating devices in the aviation industry, much more cost-effectively and flexibly using a near-net-shape, additive welding process.

For this purpose, an allowance model is created from the CAD data of the part to be manufactured using appropriate software, the model is digitally divided into print layers and then, as can be seen in the illustrations above, print layer by print layer is applied using arc welding technology. As part of this feasibility study, the method of this process, known as WAAM (Welding Arc Additive Manufacturing), was transferred from conventional materials to the material 1.3912. Based on extensive work, additive layer applications, ranging from one-dimensional to multi-dimensional structures, could be implemented in line with requirements. With the help of comprehensive data acquisition and analyses, a heat-guided process system for the creation of multidimensional layer application was continuously developed. Furthermore, basic principles for order systematics and routines for complex structures have been developed. By transferring the findings to practically dimensioned components, the results serve as a reliable basis for further investigations.

CONTRIBUTION TO THE R&D PROJECT IPakU-ProIn
Title of the individual project applied for:

Process integration for the intelligent press for automated cold plastic forming

Short title:

IPakU-ProIn

Title of the joint project:

Intelligent press for automated cold plastic forming

The planned joint project will develop a functional model for a new type of system concept that can be used to automatically form large metal sheets in multiple axes. The result is a novel, intelligent product that is characterised by a new way of looking at a forming job with assignment of the forming processes and steps depending on the target contour of the workpiece. This is accompanied by an expansion of the range of applications through multi-axis forming and forecasting, an increase in the robustness of the system through adaptive pendulum damping and reliable quality control. By expanding the system functions and integrating the data management system and system safety, a demonstrator is created that forms the second phase of the new automatic press product.

Running time: 01.07.2021 until 30.06.2023

Place of realisation: Ostseestaal GmbH &Co.KG Stralsund

Total expenditure: 1.037.437,00 €

Grant from the European ERDF fund and the state of MV: 414.970,00 €

CONTRIBUTION TO THE R&D PROJECT HAKU
Title of the individual project applied for:

Development and construction of a functional model for a handling system for automated forming

Short title:

HakU-Verse

Title of the joint project:

Development of a handling system for automated cold plastic forming

The aim of the joint project is to develop and construct a functional model that will enable all the necessary components of the plant concept, such as a suitable measuring system, flexible sensor technology and process control and the appropriate
mechanical components for automated cold plastic forming. This will make a significant contribution to the creation of the automatic press as a new product.

Running time: 01.10.2016 until 30.09.2020

Place of realisation: Ostseestaal GmbH & Co. KG Stralsund

Total expenditure:
1.523.933,00 €

Grant from the European ERDF fund and the state of MV: 699.580,00 €

Older projects

CONTRIBUTION TO THE R&D PROJECT KALD
Title of the individual project applied for:

Aluminium domed roof

Short title:

KALD

The aim of the feasibility study is to develop an innovative product approach for dome-shaped roofs in half-timbered construction. The dome roof should be particularly light and simple in design in order to minimise assembly costs and save resources. The product concept should also be scalable so that any diameter can be covered without recurring construction costs. The approach of complete modularity should be focussed on throughout. This means that the product concept should be based on a few basic structures to create a kind of modular system. As a result, the number of variants can be reduced to a minimum despite any product diameter, which would lead to a significant increase in cost-effectiveness in warehousing, purchasing, production control and engineering.

Running time: 01.05.2019 - 31.10.2019

Place of realisation:
Ostseestaal GmbH & Co. KG Stralsund

Total expenditure: 243.545,00 €

Grant from the European ERDF fund and the state of MV: 97.410,00 €

CONTRIBUTION TO THE R&D PROJECT HAKU
Title of the individual project applied for:

Production of functional samples of innovative propeller rotor concepts for steel agitators and tidal turbines

Short title:

FeRoSta

Title of the joint project:

Development of innovative steel propeller rotor concepts

The main problem lies in the production and production-orientated design of the complex component geometry, primarily the rotor blades, which presents Ostseestaal with a major challenge in terms of repeatable, precise and economical production. This applies to forming, trimming and joining. In addition to the complex geometry, the functional properties place high demands on the joints in terms of operational and fatigue strength. The aim of the individual project is to solve these problems by improving existing manufacturing processes and creating new innovative approaches.

Running time: 01.05.2016 until 30.04.2019

Place of realisation:
Ostseestaal GmbH & Co. KG Stralsund

Total expenditure: 1.264.965,00 €

Grant from the European ERDF fund and the state of MV: 740.690,00 €

CONTRIBUTION TO THE VOCATIONAL QUALIFICATION PROGRAMME

In the period from 25 June 2018 to 31 October 2019, the company Ostseestaal GmbH & Co. KG will carry out measures for the professional qualification of employees through service providers commissioned by it.

To this end, the state of Mecklenburg-Vorpommern has granted grants from the European Social Fund (ESF) in accordance with the „Directive on the promotion of in-service training for employees in companies (Qualification Directive)“ of 14 November 2017 (Official Gazette No. 47/2017, p. 783 ff.).