The history of IKV: tradition meets innovation We have been pioneers in plastics technology since 1950

In the current decade, IKV is actively fulfilling its role as a pioneer in plastics technology and responding to the growing challenges facing the industry, particularly in the areas of sustainability and digitalisation. A central concern is the promotion of the circular economy: numerous research projects have focused on improving recycling processes, material efficiency and the development of environmentally friendly plastic products. One example of this is the _H2 Business and Technology Forum, which was launched in 2023 and promotes dialog between the hydrogen economy and the plastics industry in order to develop joint solutions for sustainable energy concepts. In the Internet of Production Cluster of Excellence, IKV is investigating the integration of artificial intelligence in plastics processing. As consortium leader of the KIOptiPack innovation lab in the AI application hub for plastic packaging, IKV combines its expertise in the circular economy and digitalisation. AI-based applications in design, production and recycling are developed here to enable smarter and more resource-efficient production. The modernisation of the infrastructure on the Melaten campus, including the Plastics Innovation Center 4.0 (PIC 4.0), and the consolidation of all research areas at a central location has been promoting interdisciplinary cooperation between the IKV research areas and with various other research institutions at RWTH since 2022. The COVID-19 pandemic also presented IKV with major challenges. Between 2020 and 2022, not only did numerous events, including the IKV Colloquium, have to be canceled or held digitally, but teaching also had to be transferred to a digital concept. A decline in student numbers in the Department of Mechanical Engineering set in, partly due to the pandemic, which restricted the (international) mobility of students. Despite this, IKV demonstrated a high level of resilience and was able to continue the transfer of knowledge with digital and hybrid formats. In 2024, the IKV colloquium returned as a face-to-face event and dealt with the topics of the circular economy and digitalisation. With regard to young scientists, IKV implemented targeted measures in the post-pandemic period to get students and pupils interested in plastics and plastics technology. Achim Grefenstein joined IKV in 2024 as Scientific Director for Circular Economy and leads interdisciplinary projects to promote sustainable plastics processing and the circular economy. These projects combine technical innovations and address political regulations to make the plastics industry circular. With a clear focus on sustainability, digitalisation and automation, IKV will continue to set standards for the plastics industry in the coming years and further expand its role as a pioneer in plastics processing.

A generational change marks the beginning of the decade: on April 1, 2011, Prof. Christian Hopmann takes over the management of IKV, the management of the Sponsors’ Association and the Chair of Plastics Processing at RWTH Aachen University. His predecessor, Prof. Walter Michaeli, retires after more than 20 years of influential leadership of the institute. However, Michaeli remains a central figure in plastics technology thanks to his many voluntary activities in science and industry. Increasing digitalisation plays a key role in shaping the decade: at K 2016, IKV demonstrates a networked production cell for customisable, foamed and continuous fibre-reinforced plastic hybrid components. This concept illustrates the possibilities of “Industry 4.0” for plastics processing. Another highlight is a hybrid manufacturing concept for additive manufacturing, which will be presented at K 2016. It extends the range of materials to standard granulates and filled thermoplastics, combines automated additive processes with conventional technologies and enables the rapid production of large components. Digitalisation is also the focus of the Internet of Production Cluster of Excellence, which will build on the successful work of the Integrative Production Technology Cluster in 2019. Together with over 25 partner institutes, IKV is researching how intelligent data processing can be used to make production processes more flexible and efficient. Construction projects also characterise the 2010s: with the fourth construction phase, IKV’s headquarters are relocated to the Melaten Campus, while the injection moulding department remains in Aachen city centre. This move strengthens the institute’s infrastructure and offers state-of-the-art conditions for research and teaching. IKV’s work is also recognised on a personal level: in 2014, Prof. Christian Hopmann is awarded the Innovation Prize of the State of North Rhine-Westphalia. At the end of 2018, Dr. Rainer Dahlmann was appointed associate professor. His research focuses – from surface functionalisation to plasma technology – contribute significantly to the expansion of IKV’s scientific portfolio.

The 2000s marked a time of change and innovation for IKV, characterised by strategic initiatives to promote young talent, practice-oriented events and scientific excellence. In view of falling student numbers and an impending shortage of skilled workers, IKV launched the P2R initiative at the beginning of the decade. Between 2000 and 2003, the program offers workshops for children and young people in order to arouse enthusiasm for plastics technology at an early age and to motivate the next generation for scientific and technical careers. This initiative demonstrates the Institute’s commitment to laying the foundations for the sustainable development of skilled workers in the long term. In the area of strategic further training, IKV is launching the Success Factor Management conference series, a platform that combines science and practice. The event presents innovative concepts and perspectives on the strategic orientation of the plastics industry and promotes the exchange between leading industry experts and researchers. In 2003, IKV founds the Center for Plastics Analysis and Testing, KAP for short. It offers companies services for plastics analysis and damage management. The extensive equipment for testing the mechanical, physical, chemical and morphological properties of plastics and the associated qualified personnel are housed in the new laboratories that were created in the third construction phase at Melaten. A milestone in IKV’s scientific work is the successful participation in the first Cluster of Excellence call in 2004. The application, which focuses on plastics technology as one of the central research fields of the cluster, convinces the international jury of experts and is funded. With the Cluster of Excellence, research is developing dynamically: new research projects, modernised buildings and state-of-the-art machinery strengthen IKV’s position as a leading institute. This status attracts students from all over the world to Aachen. The 2000s thus stand for a successful combination of promoting young talent, practical training, a growing range of services for industry and cutting-edge research that sets the course for IKV’s future.

For IKV, the 1990s marked an era of significant technological developments and an increasing focus on the issues of sustainability and resource conservation. The introduction of the Packaging Ordinance in 1991 and the associated “Green Dot” recycling system provided new impetus in plastics processing. For the first time, the private sector is made responsible for systematically collecting and recycling recyclable materials. For IKV, this opens up new fields of research into recycling and sustainable material cycles. The decade also brings significant spatial developments for IKV. The laying of the foundation stone in 1992 marked the start of the expansion of the demonstration center for fiber-reinforced plastics in the Seffent Melaten expansion area (now Campus Melaten). As early as 1993, the Fiber Reinforced Plastics department moves into the new premises, which offer ideal conditions for research and development with 1,500 m² of space. Two years later, the center is officially opened, followed by the handover of a further extension in 1998. This location development strengthens IKV as a leading institute in plastics technology and paves the way for a modern, centralised infrastructure. At the same time, IKV expands its international reach: in 1991, the EUPOCO postgraduate course “Polymers and Composites Engineering” is launched in cooperation with the Catholic University of Leuven, Belgium. This program attracts 35 students from 12 countries and underlines IKV’s role as a globally networked competence center. Scientifically, the focus is on new technologies such as gas injection technology (GIT). This process not only enables material savings and shorter cycle times, but also opens up new types of applications, particularly in combination with fiber-reinforced materials. With a patented further development, IKV is setting new standards in lightweight construction and the automotive industry. The recognition of IKV’s scientific achievements is also reflected in the 1990s: in 1996, the Technical Faculty of the University of Erlangen-Nuremberg awards Prof. Dr.-Ing. Walter Michaeli an honorary doctorate – in recognition of his outstanding contribution to plastics technology.

The 1980s brought IKV significant progress in the automation and digitalisation of plastics processing. The decade began with the founding of the Plastics Technology Group at Paderborn University of Applied Sciences under the leadership of former IKV employee Professor Helmut Potente, which allowed IKV’s knowledge and innovations to be disseminated to other universities. Over the decade of the 1980s, IKV also expanded its international contacts. Contact and exchange with the Polymer Engineering Center (PEC) of the University of Wisconsin-Madison, which is still practiced today in numerous activities, was established. A significant highlight of the 1980s was IKV’s participation in the plastics trade fair K’83. Under the motto “Factory of the Future”, IKV presented a forward-looking concept that covered the entire production chain from design to production. Visitors to the trade fair were able to experience live the software package developed by IKV for mould design, which took thermal, mechanical and rheological aspects into account in the design and represented a comprehensive approach to optimizing production quality and efficiency. In 1984, Prof. Georg Menges focused on automation and quality improvement at the 12^th IKV Colloquium. He emphasised that reproducible and automated production processes were crucial for the competitiveness of the plastics industry and that this was the only way to guarantee high and consistent quality. This sent out a strong signal for the role of automation in the field of plastics technology. The introduction of CIM (Computer Integrated Manufacturing) was another milestone demonstrated by IKV at the K’86 trade fair. Using a practical example, IKV showed how the networking of CAD, CAE and CAM systems could digitally integrate the entire manufacturing process – from design and tool production to series production. The implementation of the CIM concept enabled just-in-time production and optimised production processes for smaller batch sizes and greater efficiency, a decisive step towards flexible and economical production. Although CIM was initially ridiculed, the concepts developed by IKV formed the basis for today’s Industry 4.0 standards and laid the foundation for digital networking and automation in the plastics industry. The 1980s were therefore a formative decade in which IKV consolidated its position as an innovative driver of the industry and changed plastics processing for good. However, they also marked an important change in the management of the institute. In September 1987, Prof. Dr.-Ing. Walter Michaeli was appointed to the Endowed Chair of Plastics Processing and officially took over the management of IKV in January 1988. On the eve of the 14th Colloquium in March 1988, Prof. Georg Menges is officially bid farewell in the Coronation Hall of Aachen City Hall. Among the guests of honour was the then Federal Minister for Research and Technology, Dr. Heinz Riesenhuber.

For IKV, the 1970s were a decade of pioneering developments that paved the way for modern plastics processing and automation. At the 6th IKV Colloquium, a specially equipped injection moulding machine with a process computer was presented – an innovative, albeit cost-intensive project. Despite initial skepticism in the industry, this development laid the foundation for the automation of injection moulding technology and had a lasting impact on the industry. The press spoke of “production in ghost shifts” and the Swiss trade newspaper “Wirtschaft + Technik” ran the headline: “As if controlled by a ghost hand”, describing the machine developed at IKV as “one […] which – provided that the Mould is capable of working and the material is normal – requires no operation”. (Quote from April 16, 1981) The growing importance of IKV inevitably led to an expansion of its premises. In spring 1977, the company moved into the new building at Pontstrasse 55, on the corner of Tempergraben. With 1000 m² of floor space, it provided room for a modern injection moulding hall and new laboratories and offices. The institute’s crafts department also expanded. In its 1976 activity report, IKV was able to announce that 419 plastics training courses had been offered in the now 27 course locations in Germany and West Berlin together with the South German Plastics Center in Würzburg. Since the IKV was founded in 1950, a total of more than 50,000 participants have attended these courses. At the same time, the VDI Society for Plastics Technology was founded within the Association of German Engineers. It promoted professional exchange and further training in the field of plastics technology and helped to meet the growing demand for knowledge in the industry and promote new specialists. IKV received special media attention through an interview with Prof. Georg Menges in the run-up to the 8th Plastics Technology Colloquium in 1976. In the Aachener Volkszeitung newspaper, Menges spoke about the role of plastics and their prospects in connection with recycling, resource conservation and automation. In this remarkable interview, he outlined how plastics can be produced from a wide variety of raw materials and emphasised that plastics will play a key role in the future – even in times of raw material shortages. This interview, which was particularly topical due to the oil crisis and the environmental debate at the time, reflected IKV’s great potential for innovation and anticipated Menges’ later pioneering work in recycling. The 1970s led IKV into a phase of modernisation that laid the foundation for the coming challenges in research and sustainability.

In the 1960s, the IKV – Institute for Plastics Processing at RWTH Aachen University continued its dynamic expansion. With the inauguration of the new building in 1959, the institute gained urgently needed space for teaching and research, and Prof. A.H. Henning took over as director. As early as 1962, the IKV continued to grow and moved into additional premises in the former Kolpinghaus at Pontstraße 51. However, the growth was not without its challenges: After Henning’s sudden death in May 1964, Karl Krekeler once again took over the management of the institute until Prof. Georg Menges was appointed in 1965. Menges, with extensive practical experience in plastics processing, brought new impetus to research and teaching. On November 5, 1965, the IKV celebrated its 15th anniversary and opened new extension buildings, which provided the institute with an additional 660 square meters of space. Supported by state funds, the Volkswagenwerk Foundation and industry, the institute was able to expand its research fields such as extrusion, injection moulding, materials testing and joining technology.

Another milestone was the introduction of Menges’ lecture “Plastics Processing” in the summer semester of 1966, which saw a rapid increase in student numbers. In the same year, Menges chaired the first IKV colloquium since 1955. From then on, the colloquia took place every two years and developed into a central meeting point for experts and companies in the plastics industry. The 4th colloquium in 1968 illustrated the growth and importance of the institute. With around 750 participants, including 50 international guests, it was a great success. In close cooperation with other institutes of the RWTH, interdisciplinary contributions were made to plastics technology – from the rheological behavior of plastic melts to photogrammetry for strength testing. At the end of the decade, IKV set a new course and developed a qualification for the manufacture of plastic windows, once again underlining the institute’s practical orientation and making a further valuable contribution to industry. The encouragement from the industry was also reflected in the sponsoring association, which has now grown to 107 companies.

The history of the IKV – Institute for Plastics Processing  at RWTH Aachen University begins in the post-war period. The resumption of teaching in 1946 marked the beginning of an era of new foundations and growth. The increasing importance of plastics processing in West Germany led to the need for qualified, trained personnel for this industry. In 1949, the “Association for Welding and Allied Processes” chose Aachen as the location for plastics training. On October 27, 1950, the IKV was officially opened as part of a large colloquium. Under the direction of Prof. Karl Krekeler, the institute initially concentrated on plastics processing. The founding of a sponsoring association in 1951, initially with eight companies, including the well-known companies Bayer and Chemische Werke Hüls, gave the IKV a strong industrial basis, which enabled the institute to operate and continue to expand. A first milestone in IKV’s research work was the publication of a technical article on the welding of plastics in the trade journal “Kunststoffe” in 1952. The second colloquium was held as early as 1955, this time with a focus on application-oriented research. In the same year, Helmut König, the first engineer at the institute, received his doctorate. In the following years, the IKV continued to grow steadily. In 1956, a department for technical training and further education was created, which was organised independently of the institute’s regular operations. This department laid the foundation for the practice-oriented training that still characterises IKV today. In 1958, the foundation stone was finally laid for a new building, which was inaugurated in 1959 and provided IKV with modern space for research, teaching and administration. With the inauguration of the new building, Karl Krekeler handed over the management to A.H. Henning, thus initiating a new phase in the institute’s development.