Fraunhofer LBF unveils plastic fatigue database to accelerate development

The Fraunhofer Institute for Operational Safety and System Reliability (LBF) has created a comprehensive fatigue‑strength database for thermoplastic polymers. The repository contains data from more than 11,000 tested specimens and around 1,300 S‑N (Wöhler) curves, linking material type, processing, geometry, temperature and load conditions to fatigue behaviour. Using this data, the institute is developing a Wöhler‑line generator that can estimate fatigue curves for different temperatures, mean stresses and fibre orientations early in the design phase.

The tool aims to help manufacturers assess critical factors such as notches, temperature exposure and ageing, allowing them to plan evaluations more precisely, reduce risk and shorten development cycles. Ongoing work includes residual‑life models for repair, second‑life uses and lightweight construction. A practical example demonstrated the database’s value for a dishwasher door‑carrier that must endure 100,000 cycles at 50 °C over 18 years, with predictions confirmed by component testing.