The integration of microelectronic components into hybrid structures allows for the functionalisation by sensors, actuators and electronics, and thus, the further improvement of the performance and functional density of hybrid components. Innovative continuous manufacturing technologies for active systems based on micro- and also nanoeffects offer special advantages that enable the integration of functional elements into semi-finished products and preforms. In order to achieve the reliable integration of additional functionality, methods for the design and integration of active transducer elements in lightweight structures will be developed. The final goal is to enable the components to exhibit their intrinsic actuatory and sensory effect. A combination of in-situ and inline processes, including injection moulding with functionalised textile layers for electrical contacting and mass print technology will be used. Due to an increased use of FRP components for the reduction of energy consumption in mobile applications, the condition monitoring of these lightweight structures is of increasing importance. One highly innovative approach is that of in-situ functionalisation during production by using inmould-coating techniques and integration of nanocrystal-based sensor films. The integration of transducers and electronics into load-adapted FRP components requires novel interconnection, attachment and housing technologies. The major research objectives are the performance and reliability of signal transfer from hybrid structures to sensors and actuators, as well as the energy supply and response data linkage regarding cost-efficient production processes.
