IWC SCHAFFHAUSEN AND THE GERMAN AEROSPACE CENTER (DLR): BRINGING FIBRE-REINFORCED CERAMICS TO WATCH CASES AND FORWARD TO NEW APPLICATIONS IN SPACE

IWC SCHAFFHAUSEN AND THE GERMAN AEROSPACE CENTER (DLR): BRINGING FIBRE-REINFORCED CERAMICS TO WATCH CASES AND FORWARD TO NEW APPLICATIONS IN SPACE

Schaffhausen/Stuttgart, 8^th October 2024: In a joint development project, IWC Schaffhausen and the German Aerospace Center (DLR) have developed the first watch cases made from a ceramic matrix composite (CMC) material. Fibre-reinforced ceramics combine the hardness and scratch-resistance of conventional ceramic with the benefits of fibre composite materials, like high damage tolerance and extreme resistance to temperature shocks. The knowledge gained from this engineering collaboration helped DLR to further improve their smaller scale fibre-reinforced ceramic components for satellite propulsion systems. At an event at the DLR site in Stuttgart, representatives from the Swiss luxury watch manufacturer and the renowned research institution shared exclusive insights into their collaboration.

Since the 1980s, IWC Schaffhausen has acquired a comprehensive expertise in advanced materials. One area of focus is ceramic. The Swiss luxury watch manufacturer was a pioneer in the use of this hard, scratch-resistant material when it introduced the first wristwatch with a black zirconium oxide case in 1986. Since then, IWC has continuously innovated in the field. Important milestones included watch cases made of brown silicon nitride ceramic, black boron carbide ceramic, various coloured ceramics, and recently, a luminous ceramic called Ceralume^®. In 2013, the Swiss luxury watch manufacturer and the renowned German Aerospace Center research institution (Deutsches Zentrum für Luft- und Raumfahrt, DLR) embarked on an engineering collaboration to jointly develop the first watch cases made of a ceramic matrix composite (CMC).

Fibre-reinforced ceramic is a relatively new class of materials. It combines the advantages of conventional ceramics, like hardness and wear resistance, with additional benefits such as a very high tolerance to damage. As the material is also extremely resistant to thermal shocks, DLR had already used it for making larger rocket components and thermal protection systems for reusable space vehicles. However, the researchers were looking to adapt and practice their innovative shortf ibre pressing technology to make smaller and near net shape CMC parts, and a watch case was the perfect candidate for this endeavour. In close collaboration with IWC Schaffhausen's engineering division, XPL, the researchers at the DLR Institute of Structures and Design in Stuttgart engineered a new manufacturing process to manufacture the first IWC watch cases made of fibrereinforced ceramic. The collaboration turned out to be a success for both partners: IWC Schaffhausen was able to add CMC to its growing portfolio of advanced case materials, and, thanks to the expertise it gained working with small-scale CMC components, DLR was able to open up into new applications for space.

"The engineering collaboration with IWC Schaffhausen enabled us to demonstrate the feasibility of small, near net shape fibre-reinforced ceramic components. The knowledge we gained from working on the watch cases helped us to further develop our technology for making components for thrust chambers in satellite propulsion systems, expanding our aerospace applications", continues Bernhard Heidenreich, researcher at the Department of Ceramic Composites and Structures at the DLR Institute of Structures and Design.

A HIGHLY COMPLEX MANUFACTURING PROCESS

The starting point for producing a CMC watch case is a conventional carbon fibre-reinforced polymer. Carbon f ibres are cut up, infiltrated with a resin, pressed in a mould and baked. To make a preform in the approximate shape of the watch case, DLR employed and adapted its innovative short-fibre pressing technology. In a high temperature process called pyrolysis, lasting up to several days, the polymer matrix is subsequently converted to a carbon matrix. This results in a porous carbon fibre-reinforced carbon material. In the next step called siliconisation, silicon crystals are placed on top of the component, before it is heated in an oven. The silicon is pulled into the cavities and chemically reacts with the carbon, creating a new matrix consisting of silicon carbide ceramic. From this stage onward, the case has a hardness value of about 2400 Vickers and can only be machined using diamond tools.

INSIGHTS INTO A SUCCESSFUL ENGINEERING COLLABORATION

To share insights into this successful development project, IWC Schaffhausen and DLR organised an event at the DLR's Institute of Structures and Design in Stuttgart. Presentations by representatives from IWC and DLR explored the complex manufacturing process for CMC watch cases, while also highlighting the significance of engineering collaborations and the transfer of technology from research to new applications in different industries. The presentations were followed by a tour of DLR's research facilities, where visitors could take a closer look at the different steps in the CMC manufacturing process. IWC also showcased the Big Pilot's Watch AMG G 63 (Ref. IW506201). Launched in September 2023, this special edition Big Pilot's Watch with design cues inspired by the Mercedes AMG G-Class marked IWC's first model with a ceramic matrix composite case. As the structure of the case is determined by the fibres, and remains fully visible after f inishing with diamond tools, each watch boasts an absolutely unique matte black look.

ABOUT DLR

DLR is the Federal Republic of Germany's research centre for aeronautics and space. It conducts research and development activities in the fields of aeronautics, space, energy, transport, security and digitalisation. The German Space Agency at DLR plans and implements the national space programme on behalf of the federal government. Two DLR project management agencies oversee funding programmes and support knowledge transfer.

Climate, mobility and technology are changing globally. DLR uses the expertise of its 54 research institutes and facilities to develop solutions to these challenges. Our 10,000 employees share a mission - to explore Earth and space and develop technologies for a sustainable future. By transferring technology, DLR contributes to strengthening Germany's position as a prime location for research and industry.

• BIG PILOT'S WATCH G 63, REF. IW506201
• Developing the first watch cases made from a ceramic matrix composite (CMC) material

  Konstantin Landuris
• Developing the first watch cases made from a ceramic matrix composite (CMC) material
• Developing the first watch cases made from a ceramic matrix composite (CMC) material
• IWC Schaffhausen & DLR

  L-R: Prof. Dr Heinz Voggenreiter, Dr. Lorenz Brunner, Bernhard Heidenreich, and Chris Grainger-Herr
• BIG PILOT'S WATCH G 63, REF. IW506201
• BIG PILOT'S WATCH G 63, REF. IW506201
• BIG PILOT'S WATCH G 63, REF. IW506201
• BIG PILOT'S WATCH G 63, REF. IW506201