The demand for high-performance oxide ceramic fibers continues to grow across industries such as aerospace, automotive, and energy. Each application requires its own kind of specialized fibers with a defined combination of exceptional thermal and mechanical properties. To meet this development demand and to successfully implement the new fibers in the markets, an intermediate, pilot-scaled fiber production of 3 t per year is crucial.  

At Fraunhofer HTL, we have now successfully set up the means for supporting such an upscaling from lab-scale (< 1 kg of fibers per trial) to pilot-scale fiber manufacturing. At our unique pilot facility in Bayreuth up to 1 ton of oxide ceramic fibers can be produced annually, representing a significant advancement in development and manufacturing capabilities.  

Our pilot plant is especially designed for the conduction of feasibility studies. Industrial partners can test and improve their novel fiber compositions under near-industrial production conditions enabling the optimization of materials and processes. The facility encompasses the complete range of production steps, from synthesis through spinning to sintering, making it a versatile platform for refining the properties and performance of the fibers.

The fiber production development can be accompanied by sophisticated material and fiber characterization and beneficiation processes, such as textile fabrication and the small-scale production of ceramic matrix composites (CMCs), performed by specialized departments at Fraunhofer HTL. This integrated approach ensures comprehensive evaluation of new fiber materials, supporting their development and application in high-performance sectors.

Our presentation will discuss the challenges and solutions which can be encountered during the upscaling of oxide ceramic fiber production, focusing on the pilot facility's role in material optimization and testing. Additionally, we will highlight how the facility enables collaboration between academic and industrial partners to advance the commercialization of the novel ceramic fiber technologies.