Project description

The most important aim of this subproject is the fabrication and coating of ceramic polymer and ceramic metal composite materials with improved mechanical strength and toughness and ultra-high packing density by using the fluidized bed spray granulation process in a novel miniaturized plant. The particles are coated with a polymer in the process and the fabricated granules are assembled afterwards to bulk materials by hot pressing and final mechanical properties are characterized. The fabricated composites consist of a hard disperse phase (ceramic, metal) and a soft continuous phase (high performance polymer). The envisaged structure of composites is hierarchically designed. The pre-structured granules are supplied from projects A1 and A6 and the polymer from project A2. Next to the fluidized bed spray granulation process a nano spray drying process was identified as a suitable production process of composites. Submicron particles can be encapsulated with a polymer layer. This is followed by warm compacting and analyzing of the produced composites, as in the first process.

A multiscale simulation strategy including the discrete element modeling (DEM) for determination of mechanical properties and microstructure of the produced composite materials is applied, where two hierarchical levels will be modeled. This is done using the DEM-Software MUSEN. The additional coupling with CFD simulations of the fluid phase will allow optimizing and analyzing the influence of the process parameters on the particle formulation and the transport processes. Main material parameters are composition, shape and size of the particles as well as type of polymer.

Project leaders
Prof. Dr.-Ing. habil. Dr. h.c.
Stefan Heinrich,

fluidized bed




multiscale simulation

thermal expansion                                        sintering


1. H.S. Rothberg, S. Pietsch, G.A. Schneider, and S. Heinrich: Fabrication of Highly Filled Composites with an Innovative Miniaturized Spouted Bed. Processes 8, 521 (2020) open access

2. M. Dosta, K.P. Furlan, V. Skorych, S. Heinrich and R. Janssen: Influence of pores arrangement on stability of photonic structures during sintering. Journal of the European Ceramic Society 40, 4562-4571 (2020) open access - with C5

3. E. Eichner, P.-K. Fischer, S. Heinrich and G.A. Schneider: Production of composites with high relative permittivity using the spouted bed technique. Particuology (2018). - with A6

... and more on the list of publications.

open as PDF.