ZAL_YB-2017

ZAL YEARBOOK
2017

FUTURE.
CREATED IN HAMBURG.

ZAL
YEARBOOK 2017
CONTENTS
4 — 5
INTRODUCTION 6
Welcoming Address
Roland Gerhards, CEO ZAL GmbH 10
ZAL Highlights 2017 14
Quotes 2017 20
FACTS & INFORMATION 22
ZAL – Recognized Innovation Centre 26
ZAL GmbH – Personnel 28
ZAL GmbH – Four Core Business Areas 29
Rental & Building Operation 30
Zal Tenant DLR 34
R&T Services – Industrial Projects & Funded Projects 36
FoluHH – Aviation Research Network Hamburg 44

RESEARCH & TECHNOLOGY 46
ACHIEVEMENTS ZAL TECHCENTER
›FAMOS‹ 50
Awards 54
ACHIEVEMENTS ZAL GMBH
›WiNDroVe‹ 56
Fuel Cell Lab 58
Acoustics Lab 62
ZAL TECHCENTER 66
Insight ZAL 70
Property Management 74
Facility Management 76
Project Management 78
Workshop 80
Reception 82
Corporate Communications 84
Eventmanagement 88
CONTENTS
ZAL EVENTS 90
ZAL Innovation Days 2017 94
ZAL Science Slam 98
ZAL Imprint 102

6 — 7
INTRODUCTION

INTRODUCTION

8 — 9 8
—

INTRODUCTION

10 — 11
ROLAND GERHARDS
CEO ZAL GmbH

ZAL
WELCOMING ADDRESS
ZAL – A BEACON
OF RESEARCH
AND INNOVATION
— Dear Readers,
Last year, in the first edition of this yearbook, I announced
that now, after the successful opening, things were really
going to get moving here at the Center for Applied
Aeronautical Research in Hamburg. And I don’t think I
was promising more than we ended up delivering. One
year after its opening, ZAL has become a beacon of
research and development, visible from afar. Numerous
companies and teams have moved in, from major players
like DLR to start-ups like Synergeticon. Events have
brought our hangars to life and attracted high-ranking
guests from all over the world. The debut of our ›ZAL
Innovation Days‹ (p.94) was a prime example. I have been
privileged to welcome the widest range of visitors from
the political and industrial spheres, showing them
Underlying this dynamic life that has taken hold at ZAL
in such a short time is teamwork. Teamwork within our
GmbH entity, where we combine our efforts to create
an environment where our tenants can work and collaborate.
But above all, teamwork between tenants,
thanks to open doors and shared spaces. And after a
year of seeing it in action, I can say that our concept
works. Airbus and Lufthansa Technik joined forces at
ZAL for the ›FAMOS‹ project, funded by the Aviation
Research Program, developing a system whereby a
robotic arm applies a ›shark skin‹ structure to the wing
surface of airliners (p.50). At a workshop, Diehl and
Lufthansa Technik got together and developed a bar
module for the galley. Soon enough the project was
INTRODUCTION
»WHAT I REALLY LIKE ABOUT MY WORK IS THAT WE HAVE THE FREEDOM TO DRIVE DEVELOPMENTS AND TO MAKE
DECISIONS THAT BENEFIT THE AVIATION INDUSTRY IN HAMBURG.« ROLAND GERHARDS
through our infrastructure and introducing them to the
project teams. My colleagues and I have given interviews,
exhibited at trade fairs and presented our
concept to every imaginable interest group – and at
every opportunity, we have invited people to join in.
And now we have complete occupancy!
nominated for the Crystal Cabin Award – the industry’s
internationally renowned prize from our home town.
Furthermore, Airbus and Altran fought against complexity,
weight, and cost all at once with their Printed
Electrics concept. And they won the German Aviation
Innovation Award for it (p.54). Thanks to our network

ZAL
WELCOMING ADDRESS
12 — 13
formats such as the Business Breakfast, later contract
partners have found each other. On an international
level, too, our focus on collaboration has quickly borne
fruit. Partners from Canada and ZAL have joined forces
for joint research on cabin acoustics and fire-resistant
composite fibre components (p.62). Such projects
require passion and commitment. In the summer of
2017, to reflect and acknowledge this unique ZAL
dynamic, I took to the controls in my own aircraft. In an
aerobatics plane, all the gears simply have to mesh; in
the same way, innovation depends on all the participants
working together. Teamwork, across the boundaries
of companies and disciplines, is the foundation for
ZAL projects. This is the lift and thrust that sees us take
off afresh every day.
The aviation cluster, Hamburg Aviation, was behind this
location film I took the lead role in. Hamburg Aviation is
the umbrella brand for Hamburg as a key aviation
center, in which we have taken on the role of moderator
for the areas of research and innovation. Our goal is to
push ahead in these areas, raising their profile even
further. To achieve this, we work together closely with
companies, the cluster, universities, and the political
sphere. Our doors are always open.
Why not have a look at the film? And please be sure to
pay us a visit and have a look at ZAL. You will be amazed
at how dynamic, how alive, how effective it has so
quickly become!
Yours,
HAMBURG
Bird's-eye view on the world's
third-biggest civil aviation location
ROLAND GERHARDS
DOLLAM VOLORESCID
Antotate modit, nobis as quos et dol

INTRODUCTION
ROLAND GERHARDS
ZAL's CEO starred in a Hamburg
Aviation image clip in 2017
EVERYTHING INTERLOCKS
When private life
reflects business
ABOVE AND ON THE GROUND
Just as at ZAL, in a plane all
the gears simply have to mesh
www.zal.aero/zal-live/videos

ZAL
HIGHLIGHTS 2017
ZAL 2017
HIGHLIGHTS
PREMIERE OF ZAL INNOVATION DAYS
International conference about innovation
in aeronautics and new ways of working
Read more: p.94
14 — 15
SENATOR FRANK HORCH
Ministry for Economic Affairs in the
Free and Hanseatic City of Hamburg
Welcoming ZAL Innovation Days as Hamburg's
new flagship event for the aviation community

PAUL EREMENKO
CTO Airbus
»There has been a general evolution as to what is
considered a state-of-the-art collaborative workspace
that promotes the kind of values modern tech companies
such as ours embrace: notably collaboration, openness,
and speed« Eremenko stated when visiting ZAL
INTRODUCTION
COMPREHENSIVE OVERVIEW
Airbus shifted major R&T topics to the ZAL.
Tom Enders, CEO Airbus, visited the teams
to learn more about the current projects

ZAL
HIGHLIGHTS 2017
16 — 17
ZAL'S FIRST SCIENCE SLAM
Hosting the discipline of entertaining
and amusing science. Read more: p.98
SCIENCE SLAM
Read more: p.98

CELEBRATING THE OPENING OF TWO DLR INSTITUTES AT ZAL
l. to r.: Björn Nagel (Founding Director of the Institute for System Architecture in Aeronautics),
Prof. Pascale Ehrenfreund (Chair of the DLR Executive Board), Prof. Hans-Peter Monner (Provisional
Director of the Institute of Maintenance, Repair and Overhaul), Olaf Scholz (Former First Mayor of the
Free and Hanseatic City of Hamburg), Prof. Rolf Henke (Member of DLR Executive Board & member of
ZAL Shareholder Committee), Dirk Wiese (Representative of the Federal Bundestag, MdB), Read more: p.34
INTRODUCTION

ZAL
HIGHLIGHTS 2017
18 — 19
ZAL TENANT JETLITE RECEIVES
GERMAN INNOVATION AWARD 2017
Dr. Achim Leder (left) and his team won the
›IDL‹ in the category ›Customer Journey‹ for
their concept to mitigate jetlag. Read more: p.54
NOMINATION FOR CRYSTAL CABIN AWARD
Only one year after the opening the ZAL, the first
team based project – by Diehl and Airbus – was
nominated for a Crystal Cabin Award, the world's
most renowned award for the cabin industry.
Read more: p.54

FAMOS – INNOVATION CREATED IN ZAL TECHCENTER
Many companies from a variety of industries have tried to harness
the unique aerodynamic properties of shark skin in the technical
field. Lufthansa Technik, Airbus and partners teamed up to
implement the concept in an innovative way. Read more: p.50
INTRODUCTION
NETWORK WINDROVE – PIONEERING URBAN AIR SYSTEMS
The network, piloted by ZAL, moderates the UAS ecosystem
of the metropolitan region – unlocking commercial drone
use with Hamburg as model city. Read more: p.56

ZAL
QUOTES 2017
» Knighthood For
Hamburg's Aviation
Research. «
ANJES TJARKS Party whip ›Grüne‹, Hamburg
20 — 21
»The entire facility seems to be suffused with enthusiasm and
innovation and it will be interesting to follow the techniques coming
from this thoroughly modern building near the south bank of the Elbe
river in Hamburg.«
NEW ZEALAND AVIATION NEWS
»For the first time, we are
conducting joint research with
the industry under one roof.«
PROF. PASCALE EHRENFREUND Chair of the DLR Executive Board
»Lufthansa Technik and Airbus achieve ›shark skin‹ breakthrough.«
AIR AND COSMOS INTERNATIONAL on FAMOS

»Best prerequisite for being at the
forefront of the commercial use of
drones in Germany.«
HAMBURGER ABENDBLATT on WiNDroVe
»Hate plane noise? This lab is
trying to crack the problem!«
WIRED UK on ZAL Acoustics Lab
»The Latest Runway
INTRODUCTION
for Aerospace Technology
from around
the World.«
ADVANCED MANUFACTURING
»VR is a new way of collaboration between people and a preliminary
design – and ZAL has its own twist on it.«
AEROSPACE AND DEFENCE MANUFACTURING

22 — 23
FACTS &
INFORMATION

FACTS & INFORMATION

24 — 25

FACTS & INFORMATION

ZAL
RECOGNIZED INNOVATION CENTER
ZAL RECEIVES BVIZ
SEAL OF QUALITY
26 — 27
— ZAL officially became a ›Recognized Innovation
Center‹ on September 18, 2017. BVIZ, Germany′s federal
association of innovation, technology, and business
incubation centers, awarded ZAL its quality seal at the
annual members′ conference in Lübeck. This makes ZAL
one of 30 Recognized Innovation Centers in Germany.
The recognition process involves an auditing process that
takes several months, in which ZAL′s competencies were
examined in four different areas: business start-up and
incubation, technology transfer, economic development,
and commercial feasibility. BVIZ has standardized quality
norms that have to be met, and the qualification is valid
for a period of five years. At the end of this period, the
innovation centers may apply for a new audit.
The quality seal as Recognized Innovation Center is
gaining increasing recognition in politics and the media
as well as with customers and partner organizations.
An important reason for this is that the associated
audit for the innovation center represents an outstanding
opportunity to optimize and improve the services
offered as well as internal work processes. For example,
ZAL's in-house quality standards led to bringing in external
services for building operations this allowed the
Property Team recognized to greatly enhance reliability
in managing the building, including the reception area.
www.innovationszentren.de

PLEASED WITH THE CERTIFICATION
l. to r.: Christoph Birkel (hit-Technopark, Hamburg), Joachim Edel (ZAL GmbH),
Dr. Gerhard Raetz (Auditor BVIZ), Sören Denker (ZAL GmbH), Andrea Glaser (BVIZ), Hubertus Ebbers
(Technopark Kamen), Christina Große-Möller (ZAL GmbH), Roland Gerhards (ZAL GmbH)
FACTS & INFORMATION

ZAL GMBH
PERSONNEL
39 EMPLOYEES IN 2017
28 — 29
Male (26) Female (13)
— After substantial growth of ZAL′s workforce in 2016, a moderate development of new employees is planned for the
year 2017. At the end of 2017, ZAL GmbH had 39 full-time employees on the payroll. The largest growth in personnel
was allocated within the Property Management department to stabilize and professionalize the operation of the
ZAL TechCenter. Also, new staff enabled ZAL GmbH to offer new TechCenter-affiliated services. Since the middle of
2017 ZAL GmbH officially took responsibility to train an apprentice for office communication. Currently, a third of the
entity's GmbH team is female.

ZAL GMBH
FOUR CORE BUSINESS AREAS
2. ZAL Research
Infrastructures
Project Planning &
Operational Support
1. ZAL TECHCENTER
Rental & Building
Operation
3. R&T Services
Industrial Projects
& Funded Projects
FACTS & INFORMATION
4. FoLuHH
Aviation Research
Network Hamburg
— The core business activities of ZAL GmbH can be divided into four closely interconnected areas.

ZAL GMBH CORE BUSINESS AREAS
RENTAL & BUILDING OPERATION
30 — 31
INNOVATION PARTNERS
AM Power
Innos Sperlich
Jetlite
Pro Technicale
Synergeticon
ZAL Association
ZAL GmbH
RESEARCH INSTITUTES
DLR FA
DLR MRO
DLR TT
DLR SL
Fraunhofer IAP
Fraunhofer IFAM
HAW Hamburg
HSU
TUHH
— The number of partners in ZAL has grown from 27 to 36. Since the arrival of two newly established DLR Institutes,
System Architecture in Aeronautics and MRO in November 2017, the ZAL TechCenter is now fully tenanted.

FACTS & INFORMATION
OEMS, SUPPLIERS
3D.aero
Airbus
Airbus Group Innovation
Diehl Aviation
Liebherr
Lufthansa Technik
Parker Aerospace
Premium Aerotec
Rockwell Collins
Zodiac Aerospace
PARTNERS
3D Contech
Altran
Dassault Systems
FIT
IDS – Industrial Design Studio
SFS intec
Siemens
Solvay
Spitzner Engineers
THK
T-Systems

ZAL GMBH CORE BUSINESS AREAS
RENTAL & BUILDING OPERATION
100% OCCUPANCY OF
ZAL TECHCENTER IN 2017
32 — 33
95% tenants
5% ZAL GmbH

FACTS & INFORMATION

ZAL GMBH CORE BUSINESS AREAS
RENTAL & BUILDING OPERATION – ZAL TENANT DLR
HAMBURG, ZAL, AND
DLR – A PERFECT FIT
34 — 35
PROF. ROLF HENKE
Member of DLR Executive Board &
member of ZAL Shareholder Committee
— Dear Readers,
The German Aerospace Center and the organizations
that preceded it have had a presence here in Hamburg
since the 1950s. There is no question about Hamburg
being a traditional DLR site. I am therefore really pleased
that Hamburg has now become an official DLR base.
to the ZAL vision of tapping into the future of aerospace.
The two new DLR institutes in Hamburg are central to
the digitalization of aeronautics, as they will make it possible
to map the complexities of aircraft along the entire
length of the ›digital thread‹ – from design, through
production and operation, right up to decommissioning.
The government of Hamburg actively worked to see the
city become a fixed anchor point for DLR, establishing
a forward-looking research infrastructure with two
institutes at the ZAL TechCenter. The Institute of System
Architectures in Aeronautics and the Institute of Maintenance,
Repair and Overhaul make a fitting contribution
Every time I visit ZAL, I am witness to new projects and
ideas. But whenever new ideas are born, we have to
take into consideration the overall architecture of the
aircraft, and the air transportation system as a whole.
This is where the Institute of System Architectures comes
in, perfectly augmenting the existing impetus within ZAL.

The work of the Institute of Maintenance, Repair, and
Overhaul, focused on new maintenance and data analysis
methods, slots right in with Industry 4.0, another core topic
for many project teams at the TechCenter. The interaction
between our teams and the experts from other companies
and organizations is sure to enrich and enhance the work
and contribution of both institutes.
The long-term viability of the aviation industry depends on
the rapid development of excellent innovative industrial
products and processes – and not only in Hamburg. Competition
is intense. Hamburg wants to build on its leading position
as a development, integration, and final assembly location
for the aerospace industry. This means extending the city′s
existing research competence and innovative strength. The
new status as an official DLR base acknowledges the efforts
and achievements of existing DLR facilities. New potential
has now been created with the two new institutes, resident
at ZAL since November 2017.
DIGITALIZATION AND AERONAUTICAL RESEARCH
The two institutes focus on the ›digital aircraft‹
in the fields of system architecture and MRO
FACTS & INFORMATION
Hamburg and the German Aerospace Center – a perfect fit.
I am therefore delighted that we at DLR can play our part
in the lasting development of Hamburg and in the thriving
dynamism of ZAL. The TechCenter has been so successful
already in the year since it opened, making a name for itself
in international aeronautical research. Keep it coming!
PROF. PASCALE EHRENFREUND
Chair of the DLR Executive Board
»We are delighted that we are now represented in Hamburg, one of the
biggest hub′s of civil aviation worldwide, with two newly established DLR
institutes and to closely cooperate in ZAL with our industry partners, in
the field of application-oriented research.«
PROF. ROLF HENKE

ZAL GMBH CORE BUSINESS AREAS
R&T SERVICES – INDUSTRIAL PROJECTS & FUNDED PROJECTS
36 — 37
2 0 1 4
2 0 1 5 2 0 1 6
2 0
AUTOPRO
AUTOMATION POTENTIAL
FOR PRODUCTION & MANUFACTURING
SMART EXCITER MODULE
UTILIZING OF CABIN INTERIORS FOR
THE EMISSION OF SOUND
FUNDING: Hamburger LuFo
PARTNERS: Airbus, LHT, TUHH,
HAW, HSU
ZAL FOCUS: Autopro+ – development of a
model to evaluate potential
for automation
DURATION: 03/2014 to 02/2016
FUNDING: ZIM
PARTNER: Holmberg GmbH
ZAL FOCUS: Development of efficient
measurement methods
for integrating flat panel
loudspeakers in the cabin
DURATION: 01/2016 to 12/2018

FACTS & INFORMATION
1 7 2 0 1 8
2 0 1 9
2 0 2 0
FLIGHTLAB
FLIGHT TESTING IN
THE LABORATORY
NAKULEK
NATURAL CIRCULATION COOLING
FOR POWER ELECTRONICS
FUNDING: Lufo V/2
PARTNERS: Airbus D&S, ZAL, Novicos,
DLR, TUHH, HSU, HAW
ZAL FOCUS: EVAMAR – development of time
and costefficient measurement
processes
DURATION: 07/2016 to 06/2019
FUNDING: LuFo V/2
PARTNERS: TUHH, XRG
ZAL FOCUS: System architecture of the
liquid cooling circuit,
operative scenarios, and
aircraft integration
DURATION: 07/2016 to 06/2019

ZAL GMBH CORE BUSINESS AREAS
R&T SERVICES – INDUSTRIAL PROJECTS & FUNDED PROJECTS
38 — 39
2 0 1 4
2 0 1 5 2 0 1 6
2 0
GETPOWER
GALLEY ENERGY
TROLLEY POWER
WINDROVE
COMMERCIAL USE OF UAS IN
METROPOLITAN AREAS
FUNDING: LuFo V/2
PARTNERS: Diehl, Airbus, TUHH
ZAL FOCUS: GETops – operative
evaluation of new
technology
DURATION: 07/2016 to 09/2019
FUNDING: BMBF
PARTNERS: BWVI and air traffic authorities, various
hardware, software, and service providers
(SMEs, OEMs, and start-ups) and industrial
users, associations, and institutes
ZAL FOCUS: Understanding the value of commercial and
civil UAS technologies and services for
cities, creating a network to shape urban air
mobility topics for Hamburg
DURATION: 05/2017 to 01/2018

FACTS & INFORMATION
1 7 2 0 1 8
2 0 1 9
2 0 2 0
BILBO
FUEL CELL INTEGRATION IN THE LABORATORY
AND OPERATIONAL OPTIMIZATION
NAIMMTA
NEW ACOUSTIC INSULATION
METAMATERIAL TECHNOLOGY FOR AEROSPACE
FUNDING: BMVI, NIP/NOW
PARTNERS: Airbus, Diehl Aerosystems/
AOA, DLR TT
ZAL FOCUS: Design, construction, & commissioning
of a test stand for component
characterization in the system network
DURATION: 05/2017 to 09/2019
FUNDING: BMBF, CRIAQ
PARTNERS: 3M, Airbus, ETS, HAW, Hutchinson,
Mecanum, Canada NRC CNRC,
Sherbrooke University
ZAL FOCUS: New primary and secondary insulation
with significantly better noise level
reduction in low-frequency area
DURATION: 09/2017 to 08/2020

ZAL GMBH CORE BUSINESS AREAS
R&T SERVICES – INDUSTRIAL PROJECTS & FUNDED PROJECTS
REVENUE TECHNOLOGY PROJECTS
12,000,000 €
11,000,000 €
10,000,000 €
9,000,000 €
8,000,000 €
7,000,000 €
40 — 41
6,000,000 €
5,000,000 €
4,000,000 €
3,000,000 €
2,000,000 €
1,000,000 €
0 €
2009 2010 2011 2012
— The research and development services of ZAL
GmbH are provided by employees working in the technology
department. There are different key areas. Their
business activities can be divided into industrial and
publicly funded projects. With the opening of the ZAL
TechCenter a new form of collaboration between ZAL

EARNINGS FROM R&D PROJECTS
EARNINGS FROM CUSTOMER PROJECTS
TOTAL
FACTS & INFORMATION
2013 2014 2015 2016 2017
GmbH and its partners has been established. As a result
of this, revenues have been increased significantly. Total
revenues from technological projects in 2017 amounted
to 2.5 million euros. Of this 2.1 million euros came from
industrial projects and 0.4 million euros from funded
projects.

ZAL GMBH CORE BUSINESS AREAS
R&T SERVICES – INDUSTRIAL PROJECTS & FUNDED PROJECTS
INVESTMENTS
12,000,000 €
11,000,000 €
10,000,000 €
9,000,000 €
8,000,000 €
7,000,000 €
42 — 43
6,000,000 €
5,000,000 €
4,000,000 €
3,000,000 €
2,000,000 €
1,000,000 €
0 €
2009 2010 2011 2012

TOTAL ASSETS
FACTS & INFORMATION
2013 2014 2015 2016 2017
— With an investment volume of 2.0 million euros
in 2017 for the construction of research infrastructure
for our partners, the planned total investment
volume of 13.7 million euros as of the establishment
of ZAL GmbH has now been reached.

ZAL GMBH CORE BUSINESS AREAS
FOLUHH – AVIATION RESEARCH NETWORK HAMBURG
— The Aviation Research Network Hamburg, abbreviated
in German as FoLuHH, is one of the four business
areas of ZAL GmbH. It aids in the marketing of the ZAL
TechCenter as a cooperative research and technology
platform, organizes networking and events, and initiates
R&T alliances and projects for industrial, university, and
CONTENT-
RELATED
EVENTS
ZAL DISCOURSE
Expert speakers,
panel discussions,
and conversation
ZAL SCIENCE SLAM
Scientists present their own
research work in a given time
frame to a diverse audience
in an entertaining way
44 — 45
ZAL INNOVATION DAYS
The international flagship
event for disruptive technologies,
open innovation,
and the future of aerospace
ZAL MEETS THE TENANT
Tenants present
themselves and their
research projects
ZAL X MEETS AVIATION
Finding synergies across
industry boundaries in
a World Café format
ZAL RADAR GROUP
Developing scenarios
of the future

SME partners. FoLuHH is thus promoting open innovation
between the TechCenter′s resident OEMs, suppliers,
technology partners, research institutes, and innovation
partners, as well as numerous external companies and
organizations. The diverse event formats are a particularly
effective public relations tool. A brief look:
NETWORKING
EVENTS
ZAL AFTER WORK
Casual get-together
at the end of the
working day
ZAL BREAKFAST
MANAGEMENT
MEETING
Networking at
management level
ZAL LUNCH
CONNECTION
Eat, meet, and
get to know
one another
FACTS & INFORMATION
ZAL UNPLUGGED
Team spirit is encouraged
here, across company
lines – whether it′s with joint
development of machinery
or a sporting team

46 — 47
RESEARCH &
TECHNOLOGY

RESEARCH & TECHNOLOGY

48 — 49

RESEARCH & TECHNOLOGY

ZAL TECHCENTER ACHIEVEMENTS
FAMOS RESEARCH PROJECT
FAMOS –
A SHARK TAKES
TO THE SKIES
50 — 51
— Two of the biggest players in ZAL TechCenter, Lufthansa
Technik and Airbus, have brought a research
project at ZAL to a successful conclusion. In the FAMOS
project, the aviation companies worked together with
bwm (Bremer Werk fuer Montagesysteme) to develop
a system for using robotic arms to coat airliner wings
with a ›shark skin‹ texture. The surface, modeled on
nature, reduces airflow resistance, thereby lowering
fuel consumption.
SHARK SKIN FOR MORE
ENVIRONMENTALLY FRIENDLY AVIATION
The aviation industry has been investigating surfaces
that reduce friction and drag for several years. The
benefits of a so-called ›riblet structure‹, modeled on
the skin texture of sharks, are obvious: the improved
surface can reduce the fuel consumption of an airliner
by around 1%. For Lufthansa′s fleet alone, this would
result in a saving of 55 million euros-worth of kerosene
and more than 200,000 tonnes of CO2 each year.
EFFICIENCY IN PROGRESS
By using the riblet structure, the fuel
consumption can be reduced by about 1%

RESEARCH & TECHNOLOGY
SUCCESSFUL COLLABORATION
IN THE ZAL TECHCENTER
Airbus and Lufthansa Technik
teamed up at ZAL for FAMOS
AUTOMATED COATING PROCESS
The automation offers high quality
and cost-efficiency at the same time

ZAL TECHCENTER ACHIEVEMENTS
FAMOS RESEARCH PROJECT
52 — 53
ZAL TECHCENTER HANGAR C
FAMOS project area

TECHNICAL PREPARATION
Adjusting the robotic arm
for the coating process
FAMOS – AN AUTOMATED GUIDANCE
SYSTEM FOR THE APPLICATION OF RIBLETS
Until now, the application of the ›shark skin‹ structure
to larger surfaces has proven difficult. Since 2014, the
FAMOS project has been researching a solution that
allows even large areas such as wings to be painted and
coated using a robotic arm; the automation means that
the work is cost-efficient without sacrificing quality.
IDEAL RESEARCH CONDITIONS
IN ZAL TECHCENTER
With the large hangar facilities of the ZAL TechCenter, for
the first time the project partners – Lufthansa Technik,
Airbus and bwm – now had access to the ideal setting
for transferring the findings from theory to practice by
building a demonstrator. The method involved a special
paint, developed by Airbus in collaboration with paint
suppliers, being applied to the surface as a ›shark skin
structure‹ and then hardened using UV light. Cleaning
the surface beforehand and removing old paint is also
possible without difficulty. FAMOS is an acronym for
a German product name meaning ›Guidance System
for Automated Application of Multifunctional Surface
Structures‹.
ZAL AN INNOVATION PLATFORM
FOR SUCCESSFUL COLLABORATION
»The fact that such respected aviation companies as
Airbus and Lufthansa Technik are conducting joint
research here on very specific issues for the future
shows the acceptance that ZAL has found and underlines
Hamburg′s global competitiveness,« said Roland
Gerhards, CEO of ZAL GmbH. The project was funded
as part of the Federal Ministry for Economic Affairs and
Energy′s fifth Aeronautical Research Program (LuFoV)
since 2014. Now that the project has come to a successful
conclusion, including the construction of a functional
demonstrator in the ZAL TechCenter, the next step is to
tackle the industrialization of the technology. And the
great benefit of this research cooperation in Hamburg?
Both of these major players can deliver the technology
they have developed in the ZAL TechCenter to their
customers – Airbus in the aircraft manufacturing process,
and Lufthansa Technik in maintenance.
RESEARCH & TECHNOLOGY

ZAL TECHCENTER ACHIEVEMENTS
IDL AND CRYSTAL CABIN AWARD
AWARDED
INNOVATION –
CREATED AT ZAL
54 — 55
— The German Aviation Innovation Award (IDL) was
presented in Berlin for the second time on 29 June
2017. Two of the four winning teams came from the ZAL
TechCenter, winning over the jury with their outstanding
innovation concepts. Airbus Operations and Altran
won the ›Industry 4.0‹ category, and Jetlite won for
›Customer Journey.‹
PRINTED ELECTRICS
With its project to print electric cabling, Airbus Operations
and Altran are in tune with the trend towards
electrified aircraft. Behind the printed electronics is
a new digital technology using electrically conductive
ink, whereby wiring for data and energy transmission is
printed on the surface. The vision is to do without conventional
electrical wiring in the future. This will reduce
material requirements, save space, and achieve enormous
weight reductions. The number of components
can be reduced by up to 70%.
In the future, printed electrics could replace the cabling
for air-conditioning, data transfer, and lighting. As the
new technology is easier to integrate, it makes possible
more flexible and individually customized cabin design
for airline needs and wishes.
JETLITE FIGHTS JET LAG
The Jetlite start-up, based at ZAL, aims to reduce the
effects of jet lag arising from long-haul flights. With the
help of an algorithm based on scientific data, Jetlite has
succeeded in counteracting jet lag with cabin lighting
and nutritional concepts optimized for the human biorhythm.
This substantially increases passenger comfort.
Jetlite′s lighting concepts are already being deployed by
Lufthansa.
GALLEY BAR MODULE – SIGNIFICANT ADDED
VALUE WITH JUST A FEW SIMPLE MOVEMENTS
In collaboration with Lufthansa Technik AG, Diehl, a
ZAL partner, made it to the IDL final with the Galley
Bar Module. With minimal effort, the telescopic module
can be integrated into the galley, quickly converting the
work surface into a welcome desk, a bar counter, a selfservice
station, and/or a duty-free shop. The two teams
came up with the idea for the flexible galley solution
at a ZAL workshop, and it took them all the way to the
final of the 2017 Crystal Cabin Awards, too – Hamburg′s
industry award for innovation in the aircraft cabin, initiated
by the Hamburg Aviation cluster.

RESEARCH & TECHNOLOGY
ANDRÉ HUBERT, GUIDO KAISER, DENNIS HAHN all Airbus, MAX SEISSLER Altran
Meeting complexity, weight and costs with individual printed electrics.
The concept won the ›Industry 4.0‹ category at the German Aviation Innovation Award (IDL)
GALLEY BAR MODULE
by Diehl and Lufthansa Technik
Creates multiple spaces and in doing so considers
the needs of passengers, crew, and airlines alike

ZAL GMBH ACHIEVEMENTS
WINDROVE PROJECT
WINDROVE –
HAMBURG′S NETWORK
FOR UNMANNED
URBAN FLYING
56 — 57
— URBAN AIR MOBILITY – metropolitan travel in the
third dimension – is changing and developing at a rapid
rate. As urban populations grow, cities have to find answers
to pressing questions about the future of metropolitan
life. One of those questions is how urban airspace
can be made accessible in a safe and fair way for
commercial application.
The WiNDroVe network's name comes from a German
acronym for ›Commercial Use of Drones in Metropolitan
Areas.‹ It was established to analyze and further develop
the framework for the commercial usage of so-called
Unmanned Aerial Systems – UAS. The aim of this
Hamburg initiative is twofold: to shine a light on the
opportunities and hurdles for drone-based air transport
in cities, and to open new, potentially commercial,
areas of application. Projects aren't only looking at the
technology; consideration is also given to society′s
needs and regulatory requirements in a major city. The
network's initiation phase is sponsored by the SME
innovation forum of the Federal Ministry of Education
and Research (BMBF), ›Innovationsforum Mittelstand.‹
Christina Grosse-Möller, ZAL Innovation and Project
Manager, is driving the project. ZAL′s role is to provide
a neutral platform and to coordinate networks that
cross organizational and cluster boundaries. In this
sense, Christina′s task is to tie together the shared
interests and problems of the extensive and diverse
drone community in Hamburg. Representatives of industry,
universities, and regulatory authorities gather
at ZAL for regular workshops and conferences, working
on possible application scenarios for UAS in the
metropolitan region. The potential applications are diverse,
including inspection and maintenance of major
infrastructure such as port bridges, buildings, and wind
turbines, film and photography, time-critical medical
and pharmaceutical transport, to name just a few.

CHRISTINA GROSSE-MÖLLER
Innovation and Project Manager WiNDroVe, ZAL GmbH
»I AM UTTERLY CONVINCED THAT THE HAMBURG METROPOLITAN REGION IS PREDESTINED TO
PLAY A PIONEERING ROLE IN THE AREA OF ›URBAN UAV DEPLOYMENT‹. WITHIN A RADIUS OF 25
KM, WE HAVE EVERYTHING THAT COULD BE NEEDED: RESIDENT UAV EXPERTS, EXTENSIVE AERO-
SPACE COMPETENCE, AND A DIVERSE RANGE OF APPLICATIONS (INCLUDING PORT, LOGISTICS,
THE CONSTRUCTION INDUSTRY, AND THE CREATIVE ECONOMY). AND WE HAVE A GOVERNMENT
RESEARCH & TECHNOLOGY
AND AUTHORITIES THAT SUPPORT INNOVATION.« CHRISTINA GROSSE-MÖLLER
UAS CITY HAMBURG
Live demonstration of a UAS operation
of WiNDroVe partner Globe UAV

ZAL GMBH ACHIEVEMENTS
FUEL CELL LAB
FUEL CELL RESEARCH –
A FIELD THAT CROSSES
INDUSTRY BOUNDARIES
58 — 59
— The Fuel Cell Lab has a special position compared
to other research areas at ZAL. It is the only research
area not focused exclusively on aerospace, but rather
open for partners in other industries – for example the
automotive and shipping industries. Research into possibilities
for safe civilian use of hydrogen is a purpose
shared by all researching partners; ultimately, the aim
is to accelerate the technological maturity of fuel cell
systems.
Cross-sectoral research makes sense in view of the global
challenge to make mobility and energy supply more
efficient in the future whilst minimizing emissions. Technology
areas such as hydrogen, fuel cells, and batterypowered
electric motors offer great potential for clean
mobility along with efficient generation of electricity and
heat; these technologies also have a role to play in the
storage of renewable energies.
FUEL CELL DISCOURSE AND FUEL
CELL RESEARCH AT ZAL
Dr. Sebastian Altmann has been ZAL′s expert on hydrogen
and fuel cell research since 2011. He was one of the
first employees at ZAL GmbH. Already five years before
the opening of the TechCenter and the Fuel Cell Lab in
2016, he was promoting the field. The successful ZAL
Discourse series of events, now with a very broad subject
base, began as the ›Fuel Cell Discourse‹, moderated
by Sebastian Altmann. The well-known and well-loved
Discourse format, consisting of lectures, panel discussion
and a get-together focused on interaction between
all participants, proved popular with Hamburg′s
hydrogen community. An information exchange was
developed in collaboration with the Hamburg Hydrogen
Society, HySolutions, the GIC fuel cell network and
many other players.

»IN OUR BILBO RESEARCH PROJECT A LAB TEST DEMONSTRATOR, DEVELOPED IN PREVIOUS PROJECTS,
IS BEING TESTED IN AN EXTENDED LABORATORY ENVIRONMENT. THE USE OF VACUUM PUMPS AND AIR-
CONDITIONING UNITS RECREATE CERTAIN ASPECTS OF AN AIRCRAFT AS OPERATING ENVIRONMENT,
SIMULATING, FOR EXAMPLE, THE ATMOSPHERIC PRESSURE AT AN ALTITUDE OF 12,000 M OR THE OUTSIDE
TEMPERATURES IN WINTER.« DR. SEBASTIAN ALTMANN
RESEARCH & TECHNOLOGY
DR. SEBASTIAN ALTMANN
Fuel cell research expert, ZAL GmbH, working at BILBO test bench

ZAL GMBH ACHIEVEMENTS
FUEL CELL LAB
60 — 61
FUEL CELL LAB
Control station for safe and
reliable lab operation
READY FOR USE
Distribution of hydrogen,
oxygen, and nitrogen
FUEL CELL LAB
Fuel cell system components
for test purposes

FUEL CELL LAB
The TechCenter houses a 1,200-square-meter research
area well-equipped for fuel cell research. Facilities include
exhaust air systems along with piped gas supplies for
hydrogen, oxygen, nitrogen, and oil-free compressed air.
One special feature of the infrastructure is the option of
feeding energy generated by the fuel cell systems back
into the local electric grid. Various industrial and scientific
partners shared the Fuel Cell Lab in 2017, including Airbus,
the German Aerospace Center (DLR), Parker, Hamburg
University of Technology, and ZAL GmbH.
RESEARCH PROJECT: BILBO
Sebastian Altmann serves as an expert advisor to many
of the joint research activities, and he leads the Bilbo
project on behalf of ZAL GmbH. In this project, together
with Airbus, AOA and DLR, he is researching ›fuel cell
integration and operational optimization in the lab‹
(German acronym: BILBO). The goal is to create a broad
basis for the use of hydrogen and fuel cells on board
civil aircraft and also at the airports to stimulate
consumption but also acceptance. A consortium of
experienced partners is collaborating to enhance fuel
cell systems for specific commercial applications, e.g.
an environmentally friendly fire-extinguishing system.
Innovative ideas on functional models are being developed,
too, aimed at providing fresh stimuli in the aerospace
sector.
The first results of the project confirm that the special
environment presented by flight operations does not
necessarily limit the deployment of fuel cell systems;
on the contrary, functional technical solutions exist, in
some cases without any loss in performance. This, in
turn, makes the deployment of hydrogen and fuel cells
in aviation an interesting option for reducing emissions
and increasing efficiency. The lengthy development
phase means that we should not expect a flurry of activity
on the market in the short term, but discussion of
the technology is having a significant positive impact on
visibility and on the awareness of its potential.
RESEARCH & TECHNOLOGY
FUEL CELL LAB
Infrastructure interface
to customers

ZAL GMBH ACHIEVEMENTS
ACOUSTICS LAB
ACOUSTICS LAB –
ACOUSTIC FLIGHT TESTS
ON THE GROUND
62 — 63
OUT OF THE BOX
Dr. Kay Kochan and his team are working
on applied acoustics solutions

»THE MOST UNPLEASANT NOISE OCCURS IN THE TAKE-OFF PHASE, IMPACTING THE GENERAL
COMFORT OF PASSENGERS. ESSENTIALLY, IT IS PRECISELY THIS CABIN NOISE THAT WE ARE
SIMULATING AND INVESTIGATING IN OUR ACOUSTICS AND VIBRATION TESTS, WITH THE AIM
OF ACHIEVING MORE ACOUSTIC CABIN COMFORT IN THE FUTURE. THIS INCLUDES INSULAT-
ING AGAINST BACKGROUND NOISE AS WELL AS QUALITATIVE IMPROVEMENT TO CABIN AUDIO
SYSTEMS.« DR. KAY KOCHAN
— On 1 March 2015, Dr. Kay Kochan entered the
Acoustics Lab for the very first time – in Wellington
boots and with a safety helmet on his head. The
first concrete walls for the research facility had
just been erected. Since the completion of ZAL,
Kay Kochan has been working together with his
colleagues, Benjamin Becker and Matthias Weber,
on optimizing cabin acoustics and conducting
acoustic tests. What makes acoustics research
at ZAL so special is the so-called Acoustic Flight-
LAB Demonstrator, a generic aircraft rump
fuselage with the dimensions of an A320. This,
together with an array of loudspeakers for noise
generation, serves as a test stand that enables
researchers to conduct acoustics and vibration
tests on the ground. This is a revolutionary opportunity
to replace the laborious and very expensive
airborne flight tests. The ingenious construction
of the Acoustics Lab, with its acoustic free field,
the demonstrator, and its vibration-free mounting
on stilts, combined with the flexible sound system
to generate noise in the fuselage, facilitates laboratory
tests in conditions that are almost identical
to reality.
DR. KAY KOCHAN
Acoustics expert, ZAL GmbH
RESEARCH & TECHNOLOGY

ACHIEVEMENTS ZAL GMBH
ACOUSTICS LAB
64 — 65
INNOVATIVE MEASURING
METHODOLOGY AS RESEARCH AREA
The ›EVAMAR‹ research project shows that this is not
enough in terms of optimizing acoustics research. In
collaboration with seven other research partners, including
Airbus, Hamburg University of Technology, Hamburg
University of Applied Sciences, and the Helmut Schmidt
University, ZAL is currently developing a non-contact
vibration measurement methodology. Vibrations and airborne
sound are both measured. Whereas conventional
measurement processes require the working capacity of
four persons for up to two weeks for the instrumentation
in order to determine the natural oscillation mode
of the fuselage, the newly developed procedure takes
just 30 minutes for one test – a significantly quicker and
more economical solution. The improvement of measurement
processes and research into how they can be
implemented in the Acoustics Lab are making it possible
to extend our knowledge in a way that will have a great
influence on the cabin acoustics of tomorrow.
WHEN SURFACES REPRODUCE AUDIO SIGNALS
The ›Smart Exciter Module‹ research project is exploring
the use of surfaces in the aircraft cabin to emit audio
signals. An exciter (acoustic transducer) mounted on the
rear of the panels causes the cabin trim panels to vibrate.
The panels thereby replace the membrane in a conventional
loudspeaker. This creates a so-called flat panel
speaker. Examples of audio signals in the aircraft cabin
are announcements by the cabin crew, warning tones, and
music. The research project is being conducted by ZAL
GmbH in association with Holmberg GmbH & Co. KG, a supplier
of electro-acoustic components for aircraft cabins.
HIGH-END STANDARDS
The ZAL offers equipment and
expertise for acoustic testings

INTERNATIONAL COOPERATION IN
THE FIELD OF ACOUSTIC INSULATION
Metamaterials for acoustic insulation represent another
area of research, being explored in the ›NAIMMTA‹ research
project. The advantage of these innovative, lightweight
foams and glass wool bundles, installed between the primary
structure and the lining, is that they provide acoustic
insulation in specific frequency ranges while significantly
reducing weight. Relatively heavy insulation is currently
used to block engine noise in the cabin. This research
project is being conducted by ZAL GmbH as project lead,
in collaboration with Airbus, Hutchinson, Hamburg University
of Applied Sciences, and international partners from
Canada – NRCC, 3M, Mecanum, University Sherbrooke and
Montreal′s École de Technologie Supérieure.
MATTHIAS WEBER
Acoustics expert, ZAL GmbH
RESEARCH & TECHNOLOGY

66 — 67
ZAL
TECHCENTER

ZAL TECHCENTER

68 — 69

ZAL TECHCENTER

70 — 71
ZAL TECHCENTER
OUTSIDE

ZAL TECHCENTER

72 — 73
1
ZAL GmbH: The Entity
3
Cabin & Cargo Test Rig
5
Additive Manufacturing
2
Maker Space & Workshop
4
Automation
6
Virtual Reality Lab & Server

ZAL TECHCENTER
INSIGHT
ZAL TECHCENTER
7
8
UAS Technology
Acoustics Lab
9
10
ZAL Technology Lab
AVANT Test Rig
11
12
Laser Shock Peening
Fuel Cell Lab
13
FOLUHH – Aviation Research
Network Hamburg

ZAL TECHCENTER
PROPERTY MANAGEMENT
PROPERTY MANAGEMENT –
FOUR SERVICE TEAMS FOR
ONE BUILDING
74 — 75
ZAL TECHCENTER
Rear View
— ZAL GmbH′s Property Management is responsible for
the provision, reliability, and security of all building infrastructure
and services within the TechCenter′s 26,000
square meters of floor space. Head of Property Management,
André Kohlhoff, has a team of eight specialists,
organized into four separate areas: Facility Management,
Project Management, and the two service areas Workshop
and Reception.
A COMMON CREED – SATISFIED BUILDING USERS
Flexible workspaces, shared infrastructure, intercompany
projects – the very nature of the TechCenter means that
the number of people in the building will vary from day to
day. The facility is fully tenanted, but not all the 600 workspaces
are occupied every day. Networking is the be-all
and end-all in research, and people who work at the Tech-
Center travel a lot. On the other hand, a lot of visitors and
research partners, who don′t have assigned workspaces,
come here. It′s not unusual for more than 350 visitors to
be in the building on any one day. But for the Property
Team, it makes no difference whether building users are
guests or staff; the aim is always to make them happy.

ZAL TECHCENTER
ANDRÉ KOHLHOFF
Head of Property Management, ZAL GmbH
»WE SEE OURSELVES AS SERVICE PROVIDERS. WE OPERATE THE ZAL TECHCENTER AS A BUILD-
ING, AND WE ARE CONTINUALLY IMPROVING AND ENHANCING IT TO KEEP PACE WITH BOTH
TECHNOLOGY AND THE CHANGING DEMANDS OF RESEARCH.« ANDRÉ KOHLHOFF

ZAL TECHCENTER
FACILITY MANAGEMENT
76 — 77
FRED GARBE, SINA ASHGEVARI, ANDRÉ KOHLHOFF
Property: projects are typically managed outside the office
1. FACILITY MANAGEMENT – LOOKING
AFTER 350 TECHNICAL FACILITIES AND MORE
Facility Management is taken care of by Fred Garbe,
who keeps the entire building and building-related
technical equipment in order. And there are around 350
items of technical equipment in this building! This
includes heating, ventilation, and cooling systems as
well as fire and intruder detection, to name but a few.
Fred′s main focus is on the functionality of the systems
and the building itself. In his everyday routine, this
means a lot of coordinating external technicians and
contract workers as well as the in-house workshop
team. The work is complex and diverse, encompassing
maintenance, inspections, modifications, renovations,
and the supply of utilities – gas, water, electricity, cooling,
and heating.
Fred also maintains the building itself. Alongside the
internal spaces, the TechCenter also covers 13,000
square meters of external space. External service providers
perform the work of cleaning, gardening and outof-hours
building security.

»THERE ARE 350 ITEMS OF TECHNICAL EQUIPMENT IN THE TECHCENTER. THIS INCLUDES HEATING, VENTILATION,
AND COOLING SYSTEMS AS WELL AS FIRE AND INTRUDER DETECTION, TO NAME BUT A FEW. AND FROM EXPERI-
ENCE I CAN SAY, THERE IS ALWAYS SOMETHING TO DO. MY FOCUS IS ON KEEPING THE EQUIPMENT RUNNING
WITHOUT DISRUPTION. THAT MEANS THE BUILDING CAN RUN PROPERLY, AND THAT, IN TURN, MEANS THAT WE
ARE OFFERING A PERFECT WORKPLACE FOR OUR TENANTS.« FRED GARBE
ZAL TECHCENTER
FRED GARBE
Maintenance of electrical
power supply
HEATING SYSTEM
Preventive control
and regulation

ZAL TECHCENTER
PROJECT MANAGEMENT
78 — 79
SINA ASHGEVARI
Project Management, Zal GmbH
Making sure the e-charging station
can be used by everyone passing
2. PROJECT MANAGEMENT OF
TECHNICAL BUILDING FACILITIES – FOCUS
ON RESEARCH INFRASTRUCTURE AND SECURITY
Sina Ashgevari is the person to speak to when it comes
to managing and coordinating modification, installation,
and expansion projec t s related to the TechCenter ′s
technical facilities. His responsibilities include the
integration of new research infrastructures along with
the maintenance and extension of existing technical
building equipment, ensuring that the building is upto-date,
comfortable, and safe. Almost all the offices,
laboratories, and hangar spaces have been remodeled
and enhanced according to user requirements. This
includes individual access control, electrical installations,
ventilation, and other technical equipment. A
special treat for both project management and tenants
is the charging station for electric cars, which entered
operation at the end of 2017. Although it is located on
the ZAL premises, it is outside the gate, so that it is
also available for external users.

SVEN HALTERMANN & SINA ASHGEVARI
Project meeting on hangar floor
ZAL TECHCENTER
REGULAR MAINTENANCE
Checking the air conditioning

ZAL TECHCENTER
WORKSHOP
80 — 81
WORKSHOP SERVICES
Sven Haltermann operating the hangar crane

3. ZAL WORKSHOP
CRAFTING AND BUILDING, TOGETHER OR ALONE
The ZAL Workshop team, consisting of Sven Haltermann,
Thomas Holst, and Stephan Moschall, works closely
together. They are the practical professionals, quickly
solving problems large and small.
What makes the ZAL Workshop so special is that it is available
to all the building′s tenants. Research partners are
free to make use of the workshop itself and all its equipment
– and to call on the know-how and expertise of the
three all-rounders as well. The research partners determine
for themselves how much support they need, for
example, to create their prototypes and demonstrators.
ZAL TECHCENTER
WORKSHOP EQUIPMENT AVAILABLE FOR ALL TENANTS
Sven Haltermann (right) & Thomas Holst, both Workshop ZAL GmbH

ZAL TECHCENTER
RECEPTION
4. ZAL RECEPTION
INDISPENSABLE – THERE IS NO OTHER WORD
Nothing would work without them. The reception is the
switchboard for everything that happens here at the
TechCenter. Internal and external ZAL partners, service
providers, visitors ... everyone knows that their questions
will be answered here and that they will get the
best support possible, no matter what. The Reception
team consists of Kathrin Bethke, Beatrix Hoche, and
Homeira Latifi. Together, they take care of visitor registration,
issuing passes, helping people find their way,
coordinating post and parcel delivery, monitoring the
gate at the entry to the ZAL site, documenting fault
reports in the building, ordering taxis – and more.
Impossible is not possible here. And that′s why these
three are the Indispensables.
82 — 83
BEATIXE HOCHE
Reception, ZAL GmbH
Distributing mail to
TechCenter tenants

ZAL TECHCENTER
KATHRIN BETHKE & BEATRIX HOCHE
Operating the front office
RECEPTION DESK
Providing a warm welcome

ZAL TECHCENTER
CORPORATE COMMUNICATIONS
MAKING THE ZAL
BRAND FLY HIGH
84 — 85
MIRIAM FLÜGGER & MARGARETA SCHERBOWITZ
Creating and utilizing a variety of marketing measures

»I AM CONSTANTLY AMAZED AT THE SUCCESS OF THIS INCOMPREHENSIBLE ACRONYM, ›ZAL‹.
FOR MANY EXPERTS IN THE INDUSTRY, ›AERONAUTICAL RESEARCH‹ AND ›ZAL‹ HAVE BECOME
SYNONYMS. AND EVEN MORE ASTONISHING IS THE FACT THAT THE GERMAN ACRONYM IS
NOW RECOGNIZED INTERNATIONALLY.« MIRIAM-JOANA FLÜGGER
— Without doubt, effective corporate communications
have been a major contribution in ZAL′s nowadays
strong brand recognition. Back in 2009, when ZAL was
first established, Miriam Flügger managed corporate
communications alone, for example developing the
company's logo. Those days are long gone. She is still
hard at work ensuring that the ZAL brand is communicated
consistently, but nowadays she is supported by
the Executive Board, by colleagues, and even by Hamburg
Aviation cluster.
The aim of Corporate Communications is to convey a
unified and consistent ZAL brand to both external and
internal audiences. This encompasses marketing, press
and public relations and events, both internal and
external. The combined effect of the various measures
and activities is to make the ZAL brand, and the motto
– Future. Created in Hamburg. – visible and tangible for
partners, stakeholders and the company′s own employees.
And that effect is essential, if ZAL is to be perceived
by the political authorities for what it is: a functional
moderator and facilitator of aerospace research and
innovation within the Hamburg Aviation network.
AIRCRAFT INTERIORS EXPO
a must-attend event for ZAL
TECHCENTER GROUND BREAKING CEREMONY
its all about the perfect staging
ZAL TECHCENTER

ZAL ZECHCENTER
CORPORATE COMMUNICATIONS
The biggest challenge for Miriam and her team is to see
the big picture, and to maintain an overview of current
research projects for ZAL GmbH and the TechCenter
partners, without losing sight of the details and of the
milestones in individual projects. At the same time, they
are busy identifying relevant topics, e.g. advertizing and
managing events or announcing the establishment of
new research infrastructures or the arrival of new Tech-
Center tenants.
COMMUNICATION A WIN-WIN FOR ALL PARTNERS
What is all this communication for, anyway? One aspect,
of course, is gaining the attention of company executives
and politicians to generate research funding.
Spreading ZAL′s scientific reputation as a successful
research platform is another aspect, because it attracts
experts and research partners. This, in turn, is the key
to turning a small idea into an international research
project, as has recently happened with ZAL Acoustics.
86 — 87
»POWERPOINT PRESENTATIONS, AFTER-WORK HOT DOGS, LANYARDS, SPECIALIST DISCOURSES AND
INFO FLYER ... THERE ARE SO MANY DIFFERENT LEVELS OF COMMUNICATION. BUT MY ABSOLUTE
FAVOURITE TOOL FOR COMMUNICATING THE ZAL BRAND, IS OUR ZAL PEN! IT′S PERFECT FOR PEOPLE
WHO WORK CREATIVELY. RESEARCHERS KNOW BETTER THAN MOST THAT THE ROAD TO INNOVATION
HAS PLENTY OF DETOURS. TRIAL-AND-ERROR IS THE ORDER OF THE DAY. WITH OUR PEN, THE ERRORS
CAN JUST BE RUBBED OUT, SO THAT AT THE END OF THE TRIAL WHAT YOU HAVE LEFT IS THE INNOVA-
TION!« MIRIAM-JOANA FLÜGGER
The discussions of what to do and how to communicate,
whether as a team or with the various other departments,
range from regular meetings to coffee breaks
and have-you-got-a-minute chats in the corridor. Internal
marketing measures, such as services for the tech
experts, acquiring and presenting internal projects, and
ZAL′s employee infrastructure, add to the variety of the
job. It is always a challenge to negotiate, optimize, and
schedule the wide range of topics being considered to
achieve maximum possible effect. Ideally, the topics will
complement one another rather than competing for
attention. This is particularly important when it comes
to publishing research results and announcing events.
Success for the ZAL brand means its key message being
understood and propagated by partners across the
board. The brand presents a win-win situation for every
partner. It represents a neutral research platform for
civilian aviation, a tailwind for innovation, a facilitator of
new technologies, and a global beacon for the world′s
third-largest center of civil aviation. Put simply: Future.
Created in Hamburg.

ZAL TECHCENTER
JOINT FORCES FOR A PERFECT BRAND AWARENESS
Miriam Flügger (left) teams up closely with Julia Grosser (middle)
and Lukas Kaestner from Hamburg Aviation when it comes
to optimizing ZAL's role in Hamburg's location marketing
ZAL MARKETING TOOLS
A high recognition value is obligatory

ZAL TECHCENTER
EVENT MANAGEMENT
365 DAYS A YEAR
272 EVENTS AT ZAL
88 — 89
— As Event Manager at the ZAL TechCenter, Henriette
Overbeck has a job with plenty of variety. Her responsibilities
include the coordination of all events in the building.
This includes ZAL GmbH′s own events as well as
events for tenants and external partners taking place in
the publicly accessible event facilities. And last year
there were 272 such events.
Every single event has very individual requirements, of
course. So the spectrum of what Henriette has to do is
vast. Her tasks range from advice and bookings to producing
concepts, managing participants, and supporting
events. As the central contact person, she coordinates
service providers, does the groundwork for colleagues
and partners, and deals with external customers. For
particularly demanding and extensive events, such as
Innovation Days, Henriette teams up with Katharina Bley,
event manager at the Hamburg Aviation cluster.
ZAL SUMMER FESTIVAL 2017
Gathering of all tenants
KATHARINA BLEY
Eventmanager, Hamburg Aviation
Supporting ZAL's Event Management and playing
a major role in organizing the ZAL Innovation Days

HENRIETTE OVERBECK
Event Management, ZAL GmbH
ZAL TECHCENTER
»ONE OF THE EVENT HIGHLIGHTS FOR ME THIS YEAR WAS THE SECOND SUMMER
FESTIVAL FOR THE WHOLE ZAL TECHCENTER. THIS BRINGS ALL THE PERSONNEL
FROM THE VARIOUS PARTNER COMPANIES AT THE TECHCENTER TOGETHER IN A
RELAXED SETTING. MUSIC, A BIG BBQ, AND ENTERTAINMENT SUCH AS A PHOTO
BOOTH MAKE FOR A GREAT ATMOSPHERE. THE VARIOUS VIP VISITS THIS YEAR,
FROM HIGH-RANKING INDUSTRY FIGURES TO LEADING POLITICIANS, WERE
ALSO VERY SPECIAL. EVERY VISIT INVOLVES COMPREHENSIVE NEGOTIATIONS
WITH ALL THE PARTNERS AND DETAILED ADVANCED PLANNING OF THE COM-
PLETE SCHEDULE. PARKING SPACES ARE BLOCKED AND EVERYTHING IS POL-
ISHED AND PUT INTO PLACE. AND IF THERE ARE SPONTANEOUS CHANGES OR
REQUESTS DURING THE VISIT, IT′S MY JOB TO MAKE SURE IT STILL ALL GOES
SMOOTHLY. IT COULD BE AS SIMPLE AS ORGANIZING UMBRELLAS FOR THE WALK
ACROSS THE PARKING LOT OR COMMUNICATING WITH THE PARTNERS IN THE
TECHCENTER BECAUSE OF A DELAY.« HENRIETTE OVERBECK

90 — 91
ZAL
EVENTS

EVENTS

92 — 93

EVENTS

ZAL
KEY EVENTS 2017
NEW FLAGSHIP EVENT FOR
THE AVIATION COMMUNITY –
ZAL INNOVATION DAYS
94 — 95
INNOVATION MARKETPLACE
Companies presented
their innovations on-site
— In November 2017 ZAL launched its first Innovation
Days – a new flagship event for Hamburg. The concept
of the new event format is aimed at mirroring ZAL′s role
as a collaboration platform. The Innovation Days event
serves as a place for networking and for discussing
strategic issues, future technological trends, and new
approaches and methods.
Participants from various countries and industries took
part in workshops on disruptive techniques for producing
innovation, gamification, UAVs, and robotics, and had
their choice of more than 21 excellent presentations to
attend in the auditorium. Senator Frank Horch, Ministry
for Economic Affairs, Transport, and Innovation, commented
in his welcoming address: »Just two years after

KEYNOTE: THE ART OF THE POSSIBLE
Dr. Susan Ying, President International
Council of Aeronautical Science (ICAS)
opening, ZAL is almost fully occupied. It is already home
to a whole series of highly innovative projects that have
come about from collaboration between the companies
based here. Thinking outside the box together and
changing the world through collaboration is encoded
in ZAL′s DNA, making the TechCenter the ideal host for
this event.«
The journey continues. Without a doubt, the industry
is facing one question: ›When will a robot do your job?‹
The second ZAL Innovation Days, in February 2019, will
be looking at this question, exploring the recent change
across the aviation industry. For more information, visit
www.zal-innovationdays.aero.
At the heart of the 2017 event were presentations from
21 highly respected speakers, among others:
DR. SUSAN YING, President of the International Council
of Aeronautical Science (ICAS), former Chief Integration
Officer at COMAC
In her keynote address, Dr. Ying talked about the significant
increase in complexity in the development of new
aircraft. The underlying reason is the ever-growing role
played by software and the immense volumes of data
produced. This is, however, also creating new opportunities.
The avionics of the F-35 fighter jet, for example,
now project data directly to the pilot′s helmet, providing
a much better overview of what is happening. The price
per helmet is in the region of US $600,000.
ANDREW ANDERSON, Chief Operating Officer
for the Corporate Technology Office Airbus Group
Anderson provided an overview of hybrid electric
projects within his company, ranging from studies of
urban air taxis all the way to civilian aircraft. And in the
future, Airbus will be working together with Facebook in
the HAPS segment. Andersen criticized the inordinate
length of development cycles in aviation. Thirty years is
nothing unusual, he said, whereas digital products typically
reach market maturity within 18 months.
EVENTS

ZAL
KEY EVENTS 2017
96 — 97
DR. JOHANN HOFFELNER, Chief Scientific Officer,
Linz Center of Mechatronics
Dr. Hoffelner believes that connectivity is everything.
The move from multiple development platforms to a
single platform combining research and development is
the key to producing more successful innovations more
quickly.
PROF. PETER CHIVERS, Chief Executive Officer
at the UK National Composites Centre
Prof. Chivers pointed to strategies for innovative
research facilities to bridge the ›Valley of Death‹
between scientific work and market readiness. Collaboration
between various partners can lower both
development time and financial risk.
PETER FROESCHLE, Chief Executive Officer, ARENA2036
The automotive industry′s version of ZAL, located on
the University of Stuttgart campus, brings companies
and researchers together for three-day intensive
exchange meetings. Meanwhile, the ›Startup Autobahn‹
promotes new ideas for the industry.
LARS THOMSEN, Chief Futurist, future matters
In his ›Trend Report‹, Thomsen pointed out that people
and industries often underestimate what can happen
in the course of ten years. Nokia, he said, was a prime
example. In times of ›hyper-innovation‹, change is even
quicker. Thomsen went so far as to claim that artificial
intelligence will take over driving and flying in less than
ten years. Future Matters is currently monitoring 730
companies and start-ups in the field of renewable
energies. Their innovations have great potential to
literally bring about lasting change in our world.
JOHANNES PLAUM, Head of Vehicle & Material,
German Ministries, Airbus Helicopters
Plaum provided an overview of Airbus Mobility Solutions
for urban areas. The City Airbus could be deployed as
an airborne taxi in megacities.. There will be 41 such
megalopolises in 2030, compared to just 11 in 1990, and
their public transport and road infrastructure is already
reaching its limits.
DR. FRANK ANTON, Executive Vice President eAircraft,
Siemens AG
Dr. Anton delivered fascinating insights into the ›More
Electric Aircraft‹ strategy at Siemens: By 2030, the company
wants to be in a position to offer hybrid electric
airliners with a seating capacity for up to 100 passengers.
As well as lower emissions, hybrid power for
aircraft will also mean significantly lower noise levels.
Siemens believes that, by 2050, electric powerplants
will have developed to a point where they can serve as
the principal power source in aviation.
PROF. KNUT KOSCHATZKY, Head of Competence
Center Policy – Industry – Innovation, Fraunhofer ISI
The Fraunhofer Research Campus is investigating various
approaches to Private Public Partnerships – the ZAL
modus operandi. Koschatzky gave the Innovation
Days attendees a ›campus tour‹.
STEFAN GOTTHARDT, Ambassador to the
Volkswagen Digital:Lab Berlin
Gotthard introduced the Volkswagen Digital Lab, the
Berlin incubator for the VW digital user ecosystem. The
international team, consisting of personnel from Volkswagen
and Pivotallabs, operates in pairs – and avoids the
classic communication channels of telephone and e-mail.

DR. STEFAN RIEF, Head of Competence
Center Workspace Innovation, Fraunhofer IAO
Fraunhofer′s ›Forecast 2030‹ is predicting transformation
not just in industry itself, but also in the way people
work. In the future, companies will have to work to attract
staff; employees are placing more and more importance
on the work-life balance and on flexible working models,
including flexible hours as well as multiple rather than
stationary workspaces.
ODED ISRAELI, Vice President Marketing, Mindspace
Where do we feel most comfortable? At home. This is
why Mindspace, the coworking space provider from
Israel, is busy creating flexible working spaces that are
comfortable and homelike whilst encouraging productivity.
Aided by Design Thinking approaches, the Mindspace
team are continually developing new ideas for the workspace
of the future.
EVENTS
DR. FASSI KAFYEKE, Senior Director Strategic
Technology and Innovation, Bombardier Aerospace
Kafyeke is one of the ›fathers‹ of the Bombardier CSeries.
At ZAL Innovation Days, he took his audience on a journey
through the birth of this new aircraft. The timescale
of the project became clear with the first group photos of
the development team, taken as far back as 1999!
DAVID DOYLE, Director of Personalized
Digital Experience, Lufthansa Group Airlines
David Doyle of Lufthansa revealed an airline perspective
on digital innovation projects, showcasing such developments
as the RIMOWA Electronic Bag, a joint production
with partners including Airbus Protospace.
ZAL INNVOVATION DAYS
The program had plenty to offer: keynotes,
workshops, exhibition, guided tours, breakout sessions
and a top-level evening event close to River Elbe

ZAL
KEY EVENTS 2017
THE ZAL
SCIENCE SLAM
— The ZAL Science Slam was a resounding success,
with spirited engineers and scientists competing to
win over the audience with knowledge and humor
in a limited time.
98 — 99
The curtain rose on the first ZAL Science Slam
in the ZAL TechCenter Auditorium in September
2017. Five internal ›slammers‹ who work in the
building were trying their luck, joined by two
external slammers from Hanover and Munich.
The event was completely sold out and the atmosphere
was high-spirited.
ZAL SCIENCE SLAM
Voting
The subjects in the ZAL Science Slam were very
diverse: life cycle management for liquor; what
bionics can learn from parasites; why it's hard to
fall asleep when we take our smartphones to bed;
intimate relationships with aircraft toilets; additives
for organic plastics; measuring transparent
nanoparticles; and what creative engineers can
achieve. It was an entertaining evening, and the
entertainment will continue in 2018!
The concept: At a Science Slam, scientists present
their research in an entertaining way within a prescribed
time. At the end, the audience selects a
winner. Winners are chosen on the basis of the
actual science itself, but also on the entertainment
value of the presentation, and on how easy
it was to understand. The aim is to make science
and scientific projects accessible for a broader
audience.
ZAL SCIENCE SLAM
Audience

ZAL SCIENCE SLAM
Improper use of aircraft toilets, how engineers can
be creative ... those were only a few inputs for the
first edition of the Science Slam
»BIONICS MEANS LEARNING FROM NATURE, FOR EXAMPLE FROM BIRDS, TREES, AND BONES — AND EVEN FROM
PARASITES. NATURE OFFERS A COMPREHENSIVE RANGE OF EXAMPLES WHEN IT COMES TO THE DEVELOPMENT OF
FASTENING SYSTEMS SUCH AS WALL PLUGS OR ANCHORS. A GENUINE MASTER WHEN IT COMES TO PENETRATING
AND HOLDING FAST, AND AN EXAMPLE THAT EACH ONE OF US HAS SURELY EITHER SEEN OR FELT, IS THE TICK. AND
THEN THERE ARE THE SPINY-HEADED WORMS THAT MAY BE FAMILIAR TO THOSE OF US WHO LOVE CATS, HORSES,
OR SUSHI!
WITH AROUND 2.5 MILLION TYPES OF ORGANISMS ALREADY KNOWN, NATURE OFFERS US A BROAD PALETTE OF
SOLUTIONS FOR ALMOST EVERY TECHNICAL PROBLEM. ALL WE HAVE TO DO IS LOOK AND LEARN. ON TOP OF THIS,
NATURE HAS HAD A QUALITY MANAGEMENT SYSTEM WITH ABSOLUTE EFFICIENCY IN PLACE FOR 3.8 BILLION YEARS:
MISTAKES DON’T SURVIVE. THIS APPROACH TO QM, HOWEVER, IS PERHAPS BEST LEFT TO NATURE.«
EVENTS
MARKUS HOLLERMANN Innovation & biomimetic expert, Altran. Topic of his slam: »How intestinal parasites revolutionize aircraft construction«
ZAL SIENCE SLAM
After-party

100 — 101

ZAL 2017

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PHOTO CREDITS
Airbus Operations GmbH, Jan Brandes, Bundesverband Deutscher Innovations-,
Technologie- und Gründerzentren e.V., DLR, doublevisionhh.de, Johannes
Huisman, Innovationspreis der Deutschen Luftfahrt, Lukas Kaestner,
Hamburger Kreativgesellschaft, Michael Lindner, Lufthansa Technik AG,
Daniel Reinhardt, Ben Scheurer, Simon&Paul GmbH
EDITORIAL
Lisa Becker (ZAL GmbH)
Miriam-Joana Flügger (ZAL GmbH)
Julia Grosser (Hamburg Aviation e.V., ZAL GmbH)
CONCEPT & DESIGN
Mjam Mjam Design, Hamburg
mail@mjammjam.com
www.mjammjam.com
PRINT PRODUCTION
Media Druckwerk, Hamburg
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