ZAL-YB-019

ZAL Yearbook 

2019

GENERAL INFORMATION 

LOCATION 

EMPLOYEES (ZAL GMBH) 

GENDER (ZAL GMBH) 

60 

53° 32' 18.8" N | 9° 52' 05.8" E 

55 

50 

45 

MAR–07–2016 

40 

35 

600 Persons 

30 

25 

20 

15 

54 

10 

19 

35 

www.zal.aero 

5 

0 

2009 

10 11 12 13 14 15 16 17 18 19 

SHAREHOLDERS 

RESEARCH & TECHNOLOGY 

20% 

Free and Hanseatic City of Hamburg 

20% 

Airbus Operations GmbH 

20% 

Lufthansa Technik AG 

18% 

ZAL Association for SMEs, Supply Chain and Start-ups 

10% 

German Aerospace Center (DLR) 

3% 

Technical University Hamburg (TUHH) 

Intelligent 

Robotics & Automation 

Industrial Artificial 

Data Acquisition 

3% 

Hamburg University of Applied Sciences (HAW) 

Digital Cabin 

Technology 

Intelligence 

& Processing 

3% 

Helmut Schmidt University (HSU) 

3% 

University of Hamburg 

ZAL TECHCENTER 

Fuel Cell & Electrical 

Additive 

Laser Shock 

Acoustics 

Power Systems 

Manufacturing 

Peening 

& Vibration 

ZAL Center of Applied Aeronautical Research 

Future. Created in Hamburg.

ZAL 

YEARBOOK 2019 

Facts & 

Information 


TechCenter 

24 ZAL GmbH – Personnel 

64 Research Infrastructure 

ZAL GmbH – Business Areas 

66 Occupational Safety Award 

26 Rental & Building Operation 

68 VR Tour 

4 — 5 

28 Funded Research Projects 

32 R&T Services 

34 Investments 

70 Technical Facilities 

CONTENT 

36 FoLuHH 

Introduction 

Innovation 

R&T 


Events 

10 Welcoming Address 

Roland Gerhards, 

CEO ZAL GmbH 

12 ZAL Highlights 2019 

18 Quotes 2019 

International Collaboration 

42 Transatlantic Cooperation 

43 ZAL goes SXSW 

44 A Rendez-Vous in Montréal 

46 Interview with ZAL GmbH's AM Expert 

50 Robot-Guided Additive Manufacturing 

52 AI Aviation Lab 

58 Fuel Cell Research Project 

80 ZAL Innovation Days 2019 

86 LSP Days 2019 

88 ZAL Science Slam 2019 

90 ZAL Open Lab 2019 

95 Imprint

6 — 7 

INTRODUCTION 

Introduction

8 — 9 

INTRODUCTION


WELCOMING ADDRESS 

A New Era 

Digitalization and AI at ZAL 

›IT IS A BIG BREAKTHROUGH IN INDUSTRY USING AI. BECAUSE THIS IS 

A NEW ERA WHERE THE COMPUTER ACTUALLY UNDERSTANDS THE DATA.‹ 

PROFESSOR DR. WOLFGANG WAHLSTER Director & CEO 1997–2019 German Research Center for Artificial Intelligence 

Dear Readers, 

You will notice on the following pages that the era Pro- 

Another topic presented in this yearbook is additive 

fessor Dr. Wahlster spoke about at our Innovation Days 

manufacturing (AM) – whereby this technology can 

(see quote) is for us, as an aviation playmaker, more 

also be perfectly combined with robotics, as the 

relevant than ever. 

research project ›Robot-Guided AM‹ proves. This and 

other AM projects led to the setup of an AM TechLab 

10 — 11 

The topics of AI and digitalization are currently manifesting 

themselves physically in our research center; on 

the one hand, with the installation of a fuselage assembly 

line by Airbus and, on the other hand, with the com- 

last year. The activities our experts are working on 

there is revealed to us in an interview with Dr. Thorsten 

Scharowsky, our ZAL AM expert. 

INTRODUCTION 

pletion of the AI Aviation Lab. Both infrastructures are 

And then we received a major and important award in 

reinforcing the aviation industry in terms of digitaliza- 

2019. Not just for our research work, but also for the way 

tion and smart factories. While Airbus is leveraging its 

in which we conduct research. As one of four companies 

infrastructure to pursue their technological goals and 

in Hamburg, ZAL was honored in the highest category 

collaboration, the AI Aviation Lab is geared towards all 

for occupational safety and health management. 

partners. Since the end of 2019 interested parties have 

been able to work on their topics, research them, 

We are delighted to have been distinguished with this 

and experiment with them in the new laboratory. 

award, because it confirms our mission: to provide our 

partners with ideal conditions for aeronautical research 

Just how current the topics of AI and robotics are today 

in ZAL. 

was seen at our Innovation Days 2019 event, which took 

place under the patronage of Thomas Jarzombek, Coordi- 

On this note, I hope you enjoy reading the following pages. 

nator of German Aerospace Policy. The focus ›Robotics 

Yours, 

and Advanced Automation in Aviation‹ brought together 

influential speakers from major industry players, such as 

Kuka, Siemens, Bosch, DFKI, Fraunhofer, and many more. 

PLANNING THE FUTURE 

Over the course of two days, we spoke at the ZAL Tech- 

Roland Gerhards with ZAL expansion plans. The expan- 

Center about ›Human-Machine Collaborations‹ and ›Auto- 

sion comprises three construction projects: an exten- 

mated and Autonomous Robots‹, and we experienced the 

sion of ZAL TechCenter plus a new building and car park 

current state of technology live at demonstrations. 

ROLAND GERHARDS 

on the opposite side of the street.


HIGHLIGHTS 2019 

ZAL 2019 

Highlights 

12 — 13 

AI AVIATION LAB 

ZAL GmbH opened new infrastructure 

for digitalization topics. 

Read more: p. 52–57 

ZAL INNOVATION DAYS 

How robotics and automation are changing aviation was the topic of the ZAL Innovation Days. Thomas Jarzombek, 

Federal Government Coordinator of German Aerospace Policy, visited the event in his role as patron. Read more: p. 80–85 

INTRODUCTION 

SAFER IS BETTER 

ZAL achieved certificate for 

outstanding health and safety 

conditions. Read more: p. 66–67



ROBOT-GUIDED ADDITIVE 

MANUFACTURING AT ZAL 


14 — 15 

ZAL LSP DAYS 

International laser peening experts met at ZAL. Read more: p. 86–87 

INTRODUCTION 

AIRBUS ESTABLISHES NEW RESEARCH INFRASTRUCTURE 

ZAL in August 2019: the Fuselage Industrial Line (FIL). 


TRANSATLANTIC COOPERATION 

Francois Cordeau, Vice President Transportation NRC and Roland 

Gerhards, CEO ZAL GmbH, signing the agreement. Read more: p. 42



ZAL SCIENCE SLAM 2019 

Slammers of the Hamburg Aviation 

network competed against each other. 


ZAL GOES SXSW 2019 

Roland Gerhards talked 

about flying taxis in Texas. 

Read more p. 43 

16 — 17 

ZALBATROS 

Power on for green flying. 


INTRODUCTION 

DRIVING GREEN TODAY, 

FLYING GREEN TOMORROW 

RENDEZ-VOUS IN MONTRÉAL 

ZAL GmbH pitched three topics. 

Read more: p. 44–45


QUOTES 2019 

18 — 19 

»ZAL Innovation Days 2019: 

tech-trends in aviation.« 

HAMBURG-NEWS.DE 

»Of riveting robots and exoskeletons: 

innovations in aircraft production.« 

DIE WELT 

»Aerospace is the engine 

of innovation, and the 

ZAL Innovation Days are 

the accelerator.« 

»Research cooperation 

with Canada – collaboration 

across the North Atlantic.« 

HAV MAGAZINE about ZAL Collaboration 

»ZAL is a lighthouse project for the joint 

development of projects and concepts between 

many companies in the aviation industry ... « 

AIRLINERS.DE about ZAL Innovation Days 

»ZAL project Delia focuses 

on autonomous flying.« 

HAMBURG NEWS.DE 

INTRODUCTION 

THOMAS JARZOMBEK Federal Government Coordinator of German Aerospace Policy 

»ZALamander – autonomous all-rounder.« 

BDLI NEWS Innovation of the Week 

»The future is here? At the Hamburg Center 

of Applied Aeronautical Research, aircraft 

construction reinvents itself since 2016.« 

»Robots to help with aircraft cabin 

installations, predicts ZAL.« 

SFS WHITE PAPER 

»ZAL discusses the future of aircraft production.« 

APEX about ZAL Innovation Days 

AERO-NEWS.NET about ZAL Innovation Days

20 — 21 

FACTS & INFORMATION 

Facts & 

Information

22 — 23 

FACTS & INFORMATION

ZAL GMBH 

PERSONNEL 

0 

10 

— Due to the extended scope of activities at the ZAL, 

20 

more staff was taken on in 2019, as planned, taking the 

24 — 25 

30 

number of employees from 50 to 54. 

To a large extent, the additional personnel was assigned 

to the R&T sector. 


60 

40 

50 

2019 2018 2017 2016 

54 

+4

ZAL GMBH BUSINESS AREAS 

RENTAL & BUILDING OPERATION 

TECHNOLOGY PARTNERS 

28% 

3D Contech, Altran, Dassault Systèmes, 

iDS industrial Design Studio, SFS intec, 

Siemens, Solvay, Testfuchs, THK, T-Systems 

INNOVATION PARTNERS 

25% 

3D.aero, AM Power, Innos Sperlich, 

Jetlite, LSP Technologies, proTechnicale 

Synergeticon, ZAL Association, ZAL GmbH 

26 — 27 

25% 

RESEARCH INSTITUTES 

DLR FA, DLR MRO, DLR SL, DLR TT, 

Fraunhofer IAP, Fraunhofer IFAM, 


HAW Hamburg, HSU, TUHH 

OEMS, SUPPLIERS 

22% 

Airbus, Airbus Central R&T, Diehl Aviation, 

Liebherr, Lufthansa Technik, Premium Aerotec, 

Collins Aerospace, Safran 

4x 600


FUNDED RESEARCH PROJECTS 

1. CABIN & SYSTEMS 

FUEL CELL & ELECTRICAL 

ALF Additive Manufacturing Lightweight Fuel Cell; PARTNERS: ZBT, ZAL GmbH; 

POWER SYSTEMS 

FUNDING: ZIM; DURATION: 01/2019–12/2020 

FUEL CELL & ELECTRICAL 

BILBO Fuel cell integration in the laboratory and operational optimization; 

4. NEW TOPICS 

IN INNOVATION 

1. CABIN 

& SYSTEMS 

POWER SYSTEMS 

PARTNERS: Airbus, Diehl, DLR TT, ZAL GmbH; FUNDING: BMVI, NIP/NOW; 

DURATION: 05/2017–03/2020 

INTELLIGENT DIGITAL CABIN 

DELIA Distributed Expandable Lightweight open reliable service-oriented Architecture 

for next-gen mobility; PARTNERS: Soletrix, AED, Stuttgart University, Hamburg 

University, ZAL GmbH; FUNDING: KMU-innovativ; DURATION: 02/2019–01/2022 

ACOUSTICS & VIBRATION 

FLIGHTLAB/EVAMAR Flight testing in the laboratory; PARTNERS: Airbus, 

DLR, HAW Hamburg, HSU, Novicos, TUHH, ZAL GmbH; FUNDING: LuFo V/2, 

DURATION: 07/2016–06/2019 

28 — 29 

FUNDED 

RESEARCH 

PROJECTS 

INTELLIGENT DIGITAL 

CABIN ENERGY TROLLEY 

INTELLIGENT DIGITAL CABIN 

GETPOWER Galley Energy Trolley Power; PARTNERS: Airbus, Diehl, DLR, 

Fraunhofer ICT-IMM, TUHH FST, ZAL GmbH; FUNDING: LuFo V/2; 


GETPOWER2 Operational and safety aspects of an energy trolley; PARTNERS: Diehl 

Aviation, Diehl Comfort Modules, TUHH FST, Fraunhofer ICT-IMM, Fraunhofer IISB, 

BMZ GmbH, ZAL GmbH; FUNDING: LuFo V/3; DURATION: 04/2019–12/2022 



NAIMMTA New acoustic insulation metamaterial technology for aerospace; PART- 

NERS: 3M, Airbus, ETS, HAW Hamburg, Hutchinson, Mecanum, NRC Canada, Université 

de Sherbrooke, ZAL GmbH; FUNDING: BMBF, CRIAQ; DURATION: 09/2017–08/2020 


NAKULEK Natural circulation cooling for power electronics; PARTNERS: Airbus, 

3. DIGITALIZATION 

& TECHNOLOGIES 

2.AIRCRAFT MANU- 

FACTURING & MRO 

Diehl, TUHH, XRG Simulation GmbH, ZAL GmbH; FUNDING: LuFo V/2; 

DURATION: 07/2016–06/2020 


SMART EXCITER MODULE Application of cabin interiors for passenger 

address systems; PARTNERS: Holmberg GmbH, ZAL GmbH; FUNDING: ZIM; 



UHBR2NOISE Objective methods for measuring the vibration transmission of 

economy class seats; PARTNERS: Airbus, DLR, Oldenburg University, ZAL GmbH; 

FUNDING: Lufo V/3; DURATION: 04/2019–03/2022 

1/4 15 +5


FUNDED RESEARCH PROJECTS 

AIRCRAFT MANUFACTURING & MRO 

ADDITIVE MANUFACTURING 

HUTAB Robot-guided additive manufacturing for hybrid production of 

aircraft parts on existing components; PARTNERS: COTESA GmbH, Diehl, 

HSU, ZAL GmbH; FUNDING: LuFo V/3; 

DURATION: 01/2018–02/2022 

4. NEW TOPICS 

IN INNOVATION 

1. CABIN 

& SYSTEMS 

AUTOMATION & 

IVESPA Integrated verification, sensors and positioning in aircraft production; 

ROBOTICS 

PARTNERS: Advanced Realtime Tracking, Agilion, Airbus, Fraunhofer, RWTH 

Aachen, Siemens, TWT GmbH Science Innovation, ZAL GmbH; FUNDING: LuFo V/3; 

DURATION: 01/2018–03/2021 

DIGITALIZATION & TECHNOLOGIES 

30 — 31 

FUNDED 

RESEARCH 

PROJECTS 

DATA AQUISITION 

& PROCESSING 

RESA Development of retrofittable, manufacturer-independent sensor system 

architectures for integrated, wireless measurement data acquisition, analysis 

and decision support for predictive maintenance; PARTNERS: IMST GmbH, 

Lufthansa Technik, TUHH, ZAL GmbH; FUNDING: LuFo V/3; 

DURATION: 08/2018–07/2022 


DATA AQUISITION 

RTAPHM Development of a service broker technology for drone based 

& PROCESSING 

business models and data analytics to optimize fleet availability; PARTNERS: 

Airbus D&S, Airbus, Bauhaus Luftfahrt, fortiss GmbH, Linova Software GmbH, 

TU Darmstadt, TUHH, TU Ilmenau, ZAL GmbH; FUNDING: Lufo V/3; 

3. DIGITALIZATION 

& TECHNOLOGIES 

2.AIRCRAFT MANU- 

FACTURING & MRO 

DURATION: 07/2019–12/2022 

NEW TOPICS IN INNOVATION 

UAM 

MEDIFLY-HAMBURG VLOS drone-based laboratory sample transport; PART- 

NERS: FlyNex, GLVI, Lufthansa Technik, ZAL GmbH; FUNDING: BMVI, UAS/Airtaxi; 

DURATION: 06/2019–02/2020 

3/4 

38 %


R&T SERVICES 

€ 3,000,000 

— At 1,805,000 euros, turnover from industrial orders 

reached the level projected for 2019. Revenues from 

€ 2,500,000 

R&T-funded projects, on the other hand, showed a very 

positive development in 2019. 15 executed projects and 

€ 2,000,000 

revenues of 1,038,000 euros represent an increase of 

32 — 33 

€ 1,500,000 

€ 1,000,000 

€ 500,000 

38% on the previous year. 

In the R&T area, revenues from industrial and promotional 

projects increased by 11% to 2,844,000 euros. 

Overall, the research project share grew. This is due to 


€ 0 

an increase in the number of R&T-funded projects, up 

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 

from ten to a total of 15 topics. 

REVENUES from industrial projects EARNINGS from funded research projects TOTAL 

11 % 

+5


INVESTMENTS 

— Research into aircraft air conditioning and the 

cooling of on-board electronics is an important cabin 

€ 18,000,000 

issue. For this purpose, the unique AVANT test rig 

(Architecture Validation for Air Systems of New 

€ 15,000,000 

Technologies) has been improved to become AVANT 

€ 12,000,000 

II. The climate chamber has now been added to the 

existing technical room and the stage of the AVANT 

34 — 35 

€ 9,000,000 

€ 6,000,000 

test rig. The chamber was handed over to the tenant 

Airbus in December with an investment volume of 

349,000 euros. 


€ 3,000,000 

€ 0 

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 

The AI test platform of the ZAL TechCenter, the new 

AI Aviation Lab was also completed in December. 

With an investment of 209,000 euros, the lab is 

designed to effectively bring artificial intelligence 

into aircraft production and maintenance processes. 

INVESTMENTS since 2009 

INVESTMENTS in period 

1,6 M


FOLUHH – AVIATION RESEARCH NETWORK HAMBURG 

ZAL SCIENCE SLAM 

Scientists present their own research work in a given 

timeframe to a diverse audience in an entertaining way 

— The Aviation Research Network Hamburg, abbreviated 

in German as FoLuHH, supports the marketing of the ZAL 

ZAL DISCOURSE 

Expert speakers, panel discussions and conversation 

TechCenter as a cooperative research and technology 

platform. FoLuHH organizes networking and events, and 

ZAL RADAR GROUP 

Developing scenarios of the future 

initiates R&T alliances and projects for industrial, university, 

and SME partners. FoLuHH is thus promoting open 

36 — 37 

ZAL INNOVATION DAYS 

The international flagship event for disruptive technologies, 

open innovation, and the future of aviation 

ZAL X MEETS AVIATION 

Finding synergies across industry boundaries 

in a world café format 

innovation between the ZAL TechCenter′s resident OEMs, 

suppliers, technology partners, research institutes, 

and innovation partners, as well as numerous external 

companies and organizations. 


ZAL LUNCH CONNECTION 

Eat, meet, and get to know one another 

Furthermore, the diverse event formats are a partic- 

ZAL AFTER WORK 

Casual get-together at the end of the working day 

ularly effective public relations tool. 

ZAL BREAKFAST MANAGEMENT MEETING 

Networking at management level 

CONTENT-RELATED Events 

NETWORKING Events 

8x

38 — 39 

INNOVATION, R&T 

Innovation 

R&T

40 — 41 

INNOVATION, R&T

ZAL GMBH ACHIEVEMENTS 

INTERNATIONAL COLLABORATION 


International Collaboration 2019 

42 — 43 


From left to right: DR. FRANZ JOSEF KIRSCHFINK, Managing Director Hamburg Aviation, FRANCOIS CORDEAU, Vice President Transportation NRC, 

ROBBY TECHNOW, Head of Research & Technology ZAL GmbH, ROLAND GERHARDS, CEO ZAL GmbH 

From left to right: BRIAN WYNNE, AUVSI, SUSAN YING, Ampaire, TASSILO WANNER, Lilium, ROLAND GERHARDS, CEO ZAL GmbH 

TRANSATLANTIC COOPERATION 

ZAL GOES SXSW 

— Hamburg, Germany's largest aviation hub, and Can- 

common aim is to conduct joint research on future top- 

— ZAL and Hamburg Aviation hosted a panel discussion 

Susan Ying from Ampaire, Tassilo Wanner from Lilium 

ada, one of the world's leading aviation nations, have 

ics such as the development of new maintenance and 

on Flying Taxis and Ambulance Drones at South by 

and Brian Wynne from AUVSI were the distinguished 

expanded their research cooperation. ZAL and NRC 

data evaluation methods for aircraft design (›digital 

Southwest (SXSW). The event is one of the most 

panelists of the session which was moderated by Roland 

(National Research Council of Canada) signed a Master 

twin‹) and on Urban Air Mobility. Roland Gerhards, CEO 

sought-after festivals in the USA and worldwide, where 

Gerhards, CEO of ZAL GmbH. Emphasis was on whether 

Collaboration Agreement at the largest aviation trade 

ZAL GmbH, and Francois Cordeau, Vice President Trans- 

film, music, but also media, technology, and entrepre- 

there is any substance to the much-discussed issue of 

show of the year, the Paris Air Show. NRC's and ZAL's 

portation NRC, signed the agreement. 

neurship come together. The 2019's gathering high- 

urban air mobility and on how to create a long-term 

lighted mobility in particular. 

market for air taxis and drone services in metropolitan 

regions like Hamburg.


INTERNATIONAL COLLABORATION 

MAXIMILIAN ZIETZ 

Robotics expert ZAL GmbH 

44 — 45 


FLORIAN PILLAT 

Fuel cell expert ZAL GmbH 

A RENDEZ-VOUS IN MONTRÉAL 

— Germany presented seven pitches at the Rendez- 

Vous Forum in Montréal. Three of them came from ZAL 

GmbH: the engineers pitched their ideas for collaborative 

and international research projects in UAV, Next- 

Gen Manufacturing, Maintenance, and AI. 

For the second time, CRIAQ (Canadian research network) 

had invited ZAL to the research forum. It focuses on 

innovative ideas for tomorrow's air mobility. The 

aim is to bring the aerospace industry together for an 

open innovation process. Industry leaders, researchers, 

and institutes meet there to present their ideas and initiate 

collaborative projects. 

ALAIN AUBERTIN 

President and Chief Executive Officer of CRIAQ, 

welcomed over 300 participants to the RDV Forum 2019


ZAL GMBH'S AM EXPERT 

— Dr. Thorsten Scharowsky's start at ZAL GmbH in 2016 

What are the specific advantages of additive 

coincided with the opening of the ZAL TechCenter. At 

manufacturing for the aviation industry? 

the time, he was the first additive manufacturing expert. 

Since then though the AM technology has continually 

Well, additive manufacturing can meet many require- 

Future. Printed in Hamburg. 

An Interview with 

Dr. Thorsten Scharowsky 

gained in significance and today many scientists are 

working on this topic at the research center. 

Dr. Scharowsky, did you have the feeling at the 

start of your career that additive manufacturing 

would become one of the biggest research 

topics at ZAL? 

ments. Individual parts with a batch size of one as well 

as small component series can be produced easily and 

at relatively low cost. Another advantage that additive 

manufacturing offers is optimization in design. While 

conventional manufacturing processes, such as milling 

and casting, limit the freedom of design you have with 

components, AM offers nearly all levels of freedom, as 

the technology can be adapted to the requirements of 

Yes (laughing), I certainly did! The diversity of additive 

the part. The construction of parts now takes place 

manufacturing and the application possibilities it opens 

according to specific performance criteria such as load 

up, especially for aircraft construction, are enormous. 

paths, lightweight construction, or ergonomics. 

AM is a very dynamic field in which new processes, 

materials, and applications are continually being devel- 

In addition, I think there is a lot of potential for AM in the 

oped. The spectrum of materials ranges from plastics to 

area of further development of materials. The selection 

46 — 47 

metals to material compounds, while the areas of use 

cover components for cabin applications and maintenance, 

repair and overhaul processes for jet engines. 

There's lots of scope for development! 

of available materials is currently limited and is based 

on the materials used so far. However, you must keep in 

mind that additive-manufactured alloys behave differently 

than printed ones. In many cases, better component 

characteristics can be achieved than, for instance, 


with casted components. And that is where the scope 

for improvement begins. The development of new AM 

alloys is still at the beginning and will enable new materials 

for a variety of new applications in the future. 

DR. THORSTEN SCHAROWSKY 

AM expert ZAL GmbH at AM lab 

AM TECHLAB 

Four AM machines are installed at ZAL GmbH's TechLab 

and used for research, prototyping and functional 

parts: three Fused Filament Fabrication (FFF) and one 

stereo-lithography. Furthermore, the lab is equipped 

with a 3D scanner and tooling for post-processing, 

construction and documentation software


ZAL GMBH'S AM EXPERT 

Which areas are you and your additive 

the construction space and scalability are increasing 

manufacturing team focusing on? 

enormously (read more: p. 50). Another topic is metalfused 

filament fabrication. A process that is already well 

Generally speaking, our additive manufacturing team 

established in the area of plastics, and which has the 

reflects the diversity of the technology. To be able to 

potential to manufacture metal parts at an affordable 

tap into the technology's full potential, we need an in- 

price. Research projects are currently underway that 

depth knowledge of processes, materials, and applica- 

are helping to expand the possibilities of the technol- 

tions. Our team is likewise diverse; we complement our 

ogy and ease its use in aviation. 

specialized know-how in the areas of construction, 

processes, and materials. All the team members are 

Thinking forward to the future: which issues 

experts in the process of AM and have an in-depth 

will you be dealing with at ZAL in five years? 

understanding of the process parameters and how they 

are related. With this set-up, we are able to manufac- 

All in all, you could say that knowledge centered around 

ture any component in the minimum time from a mate- 

additive manufacturing is increasing, and the processes 

rial that has been adapted to the application with an 

will become more and more self-evident and become 

optimized design for lightweight construction and 

better understood. In addition to this, trust in the tech- 

functionality. 

nology is increasingly growing. Which is why I think that 

48 — 49 

FFF PRINTER IN ACTION 

Manufacturing of a heating enclosure for the AM test rig designed in-house 

Do you have any examples of AM projects 

that you are currently working on? 

A topic that we are currently working on is robot-guided 

AM will be a standard in aviation manufacturing processes 

in just a few years. On top of this, I'm certain that 

the process chain of AM will become increasingly automated. 

In any case, the components will be significantly 

larger in the future. And then I'm quite curious to see 


additive manufacturing. In other words, the use of 

whether we will have been able to establish AM as a reli- 

industrial robots to manufacture complex parts made 

able tool in the manufacturing chain in five years' time. 

of plastic. This is exciting, mainly in terms of the component 

dimensions, since the limitations from the size of 

Thank you, Thorsten. 

CHRISTOPHER TENELSEN 

AM expert ZAL GmbH performing a quality control 

by using 3D scan, and inspecting the printer


ROBOT-GUIDED ADDITIVE MANUFACTURING 

— Tailor-made solutions in small quantities or small 

batches, functional integration and bionic design – the 

the flexible movement of the print head mounted on 

the robot; a process difficult to implement using con- 

benefits of additive manufacturing are widely recog- 

ventional printing methods, as well as retaining both 

nized. The question remains: how can additive manu- 

the process speed and construction quality of conven- 

facturing be used for large components where conven- 

tional 3D printing. 

tional 3D printers reach their limits in terms of space 

Next Generation 3D Printing 

Robot-Guided Additive 

Manufacturing 

and flexibility? In the ZAL R&T department, a small 

interdisciplinary team consisting of AM and robotics 

experts is working on answers. Their goal: not only to 

meet the existing demand for large 3D printed components, 

but also to identify new areas of utilization 

together with other aviation partners. 

The solution developed by ZAL's R&T department is an 

The current development status is impressive: in terms 

of time, a linear surface speed of 80 mm/s can be 

achieved as well as a PLA-based build-up rate of 30 cubic 

centimeters per hour. The plastics used are PLA, PC, and 

ABS (polylactides, polycarbonate, acrylic-butadiene-styrene). 

Notwithstanding this success, development is set 

to continue: high-temperature components as well as 

the application of heat to the production area should 

open test stand based on robot-guided additive manu- 

enable the use of high-performance plastics in the near 

facturing. Printing is performed by a fully automated 

future. 

industrial robot equipped with a mounted print head. A 

specially developed central control concept regulates 

The construction of the prototype set-up and its testing 

and monitors the test stand's operation. This in house- 

with high-performance polymers are funded by the 

designed test stand enables engineers to print compo- 

Federal Ministry of Economics and Energy as part of the 

50 — 51 

nents several cubic meters in volume. Further benefits 

include the ability to print on curved surfaces due to 

LuFo V-3 aviation research program. 

PROTOTYPE FOR A ROTOR BLADE 

printed at a full scale of 1.2 meters in height. 

The robot-guided AM test stand is installed at 

the TechLab of ZAL GmbH. The infrastructure 

aims at the manufacturing of large-scale polymer 

parts by Fused Filament Fabrication printing 


DR. THORSTEN SCHAROWSKY AM expert 

and TILL LUDEVIG robotics expert ZAL GmbH



Ready for Takeoff 

AI Aviation Lab 

SENSE AND SEE 

State-of-the-art vision sensors perceive surrounding objects 

52 — 53 

A LAB FOR AI AND AVIATION 



The lab invites to create and experiment 

— There is almost nothing that cannot be improved by 

it – with artificial intelligence. Thanks to algorithms and 

huge amounts of data, AI is becoming more and more 

efficient. For some time now, AI detects faces and 

speech, navigates cars and discovers cancer cells. But 

what are the effects on aviation? In order to benefit 

from AI, the different application areas must first be 

identified and then tested. It is for this reason that ZAL 

put into place the AI Aviation Lab, which opened at the 

end of 2019. 

AI IN THE AIR? 

— How do you imagine AI in aviation? Will aircraft fly 

autonomously? We are not quite there yet, but putting 

AI at the side of the pilot as co-pilot, these ideas are 

becoming more and more concrete. But already now, a 

lot is possible. Artificial intelligence can classify, detect, 

understand, reason, plan ahead, explore, navigate, and 

manipulate objects. A very promising AI technology 

these days is deep learning – a method that uses enormous 

amounts of data to create complex and effective 

models. AI & deep learning can become key technologies 

in aviation. This means that they support process 

monitoring, quality assurance or predictive maintenance. 

With their help, production rates can increase or 

the shortage of skilled workers can be solved. AI assists, 

particularly in maintenance. Using camera images, AI 

classifies damages. It also detects the construction status 

of components, systems, and aircraft. It serves as 

an assistance system for manual process steps such as 

bonding, riveting, or manual assembly. For example, it 

can also check whether engineers are wearing their 

protective equipment such as helmets or shoes. When 

it comes to flying by itself, autonomous systems in airplanes, 

drones, or air taxis are the future.



A LAB FOR AI AND AVIATION 

— The new AI Aviation Lab is a research and test play- 

An UR10e robot arm of Universal Robots enables the 

ground. It aims at everyone who wants to develop AI 

implementation of real use cases from production and 

use cases, from beginners to AI experts. The lab's infra- 

maintenance. With its three-finger gripper, for example, 

structure includes three work stations and a co-working 

it picks up tools or other objects of different geometries. 

space. Furthermore, there is a creative corner consist- 

It can also be used to carry out collaborative, sensor-sup- 

ing of a large whiteboard with seating to exchange and 

ported use cases that combine AI and robotics 

develop ideas. The corner is perfectly suitable for agile 

technologies. 

work with Kanban or Scrum boards. 

To visualize data or demonstrate results, the AI Aviation 

The technical equipment allows users to create their own 

Lab features a large 4K touch screen and a virtual reality 

AI demonstrators. The lab is equipped with a variety of 

powerwall for 2D and 3D. An intelligent operating concept 

usable sensors (high-speed cameras, depth cameras, 

allows displaying the contents of the various computers 

lidar, microphones), to record sensor data. The heart of 

on the two visualization surfaces. The lab is thus not only 

54 — 55 

the laboratory, though, is a powerful cluster of graphics 

processing units. They are designed for the training of 

deep neural networks. Here, complex AI models can be 

generated and validated. The models can be transferred 

to mobile computing units, called edge devices. They allow 

suitable for the development of AI demonstrators, but 

also for workshops, hackathons, training courses or as a 

showroom, with interactive presentation possibilities. 


AI-supported functions on a mobile platform or a drone. 

EXPLORE AND INFER 

Different visual technologies enable 

intuitive demonstration experiences 

MAKE AND DEMONSTRATE 

The lab allows its users to implement first 

viable prototypes using the provided tools 

ACT AND REACT 

A collaborative robot powered by sensors and 

adaptive algorithms makes ideas become reality



RECORD AND GENERATE 

The lab's sensors acquire training 

data rapidly. If needed, the user can 

generate data synthetically 

COMPUTE AND TRAIN 

The massive graphical computation power 

is used to train complex neural networks 

56 — 57 


IDEATE AND ENGAGE 

The Lab is a platform to create new ideas 

THE AI AVIATION LAB IN PRACTICE 

— The lab's purpose is to enable the fast implementation 

of AI prototypes for aviation. Deep learning is an 

important component in this process to detect patterns 

in data sets. This form of machine learning is used for 

example for image or speech recognition systems. 

The special feature of the AI Aviation Lab is the capability 

to carry out the entire workflow of an AI project. It has 

equipment and services along the process chain create– 

sense–compute–act–explore. This means that one can 

accomplish every step: from brainstorming, data 

recording by sensors, processing of sensor data, computation 

of neural networks to the application of robotic 

systems as well as visualization and demonstration. 

From 2020 onwards ZAL offers this environment to partners 

who are interested in realizing their own AI aviation 

projects. Depending on the development stage of the 

project, a team of experts is available for support from 

single development stages to the entire process. It's a 

rapid and effortless introduction to AI and aviation. 

CREATE AND VALIDATE 

The combination of different technologies 

allows for a fast proof-of-value


FUEL CELL RESEARCH PROJECT 

Power On 

for Green Flying 

— Electromobility is the trend. Cars, bicycles, and electric scooters are already conquering the streets. The next step 

is to continue this movement in the field of aviation, thus enabling green flying. The team of engineers is focusing on 

the use of hydrogen, which is converted into electrical energy using fuel cells. The experts successfully reached a 

milestone this summer. For the ZALbatros, the fuel cell drone, this means: ›Power on!‹ 

58 — 59 

ZALBATROS – THE HYDROGEN-POWERED DRONE 

The ZALbatros carries payloads, such as cameras or 

sensors, of up to two kilograms. It stays in the air for 

around 90 minutes. These are characteristics that far 

surpass battery-powered drones of the same size and 

drive power. 

The flexible design also makes it possible to collect data 

HYDROGEN-BASED 

PROPULSION 

SYSTEMS 

enable flight times of 

UAVs to be almost three 

times longer than with 

pure battery technology 


on the entire motor system. The ZALbatros has six 

rotors powered by two fuel cell systems with 800 watts 

FLYING LABORATORIES 

of continuous power (1,200 watts peak). The energy 

The fuel cell project is available to interested parties. It 

needed for an approximately 90-minute flight is held in 

is planned to design the ZALbatros for long-term opera- 

a 300-bar hydrogen pressure storage unit. Its operation 

tion. It will be used as a flying laboratory for new UAV 

is supported by two small battery packs, which act as a 

technologies. Drones optimize processes in industrial 

backup. 

fields such as the maintenance and repair of infrastructures. 

They help to meet the high industrial standards. 

The systems developed must be robust, reliable and 

capable of being used at any time. 

The result speaks for itself. Green hydrogen as a source 

of energy is regenerative and emission-free. Besides, it 

is characterized by a high energy density compared to 

batteries; its only waste product is water vapor. Thus, 

the team of ZAL GmbH makes its contribution to a 

future in which green flying is possible. 

ZALBATROS 

The ZALbatros drone is powered by hydrogen 

FLORIAN PILLATH 

Fuel cell expert, ZAL GmbH, at work

60 — 61 



TechCenter

62 — 63 

ZAL TECHCENTER


RESEARCH INFRASTRUCTURE 

Future Aircraft Production 

Airbus Establishes 

New Research Infrastructure 

— In recent years, aircraft production has increased 

support workers in their daily tasks. Moreover, new 

significantly. Therefore, the way in which aircraft are 

technologies such as AI and Augmented Reality help to 

built must be rethought. This process will determine the 

reduce the realization effort enormously. 

industry of the future, but also the requirements for 

aircraft construction. To meet these conditions, Airbus 

THE DIGITAL TWIN 

FUSELAGE INDUSTRIAL LINE 

The installation of the 20m long fuselage was millimeter work 

64 — 65 

established a new infrastructure in ZAL in August 2019: 

the Fuselage Industrial Line (FIL). 

The heart of FIL is a 20-meter-long A320 MSN 004 fuselage. 

It is a state-of-the-art demonstration and validation 

platform for new technologies. With this infrastruc- 

The goal is to provide a platform where engineering and 

manufacturing can work together and seamlessly share 

the same data. A digital data backbone has been set up 

for this purpose. The platform collects real-time data 

from manufacturing. New connection technologies such 

VIEW OF HANGAR A 

Cabin and Cargo Testrig and FIL (from left to right) 


ture, Airbus and its partners are aiming at an optimized 

as 5G will make this possible. The right data must be 

production in future. 

delivered in the right context, at the right time and in the 

right way. 

DIGITALIZATION AND ROBOTS 

The introduction of new technologies has a lasting 

The development of new technologies is constantly 

effect on work processes. Future digital developments 

being tested by experienced aircraft manufacturers at 

offer great opportunities. Production systems can be 

FIL. This ensures that they are suitable for practical use. 

designed, simulated and even tested to ensure a fast 

Through their feedback, innovations can be optimized 

and stable advance. New technologies such as aug- 

before they are used in production. Thus, the ongoing 

mented reality, the Internet of Things, intelligent tools 

production process is not disturbed. 

or digital assistants will be part of daily business. In the 

Fuselage Industrial Line, Airbus and other ZAL partners 

Gradually, a digital twin of the real production lines is 

like DLR, Dassault Systèmes, Fraunhofer, Synergeticon, 

thereby created. This makes it possible to digitally mon- 

ZAL GmbH etc. develop and test these digital 

itor current processes, evaluate feedback, and program 

technologies. 

new processes. These latest technologies are being 

used at ZAL, e.g. for Airbus structural assembly or the 

Robot applications in aircraft construction are also 

integration of large modules into the fuselage like a 

becoming more and more diverse. At the FIL, the part- 

cabin or a large system module. 

ners are working on lightweight robot solutions that

From left to right: 

KAI VOSS, Occupational Safety Specialist, 

ROLAND GERHARDS, CEO ZAL GmbH, 

ANDRÉ KOHLHOFF, Head of Property Management ZALGmbH, 

STEFAN JOHANNSEN and FLORIAN RENNHACK, both Health and 

Consumer Protection Authority, Occupational Safety and Health Department 


OCCUPATIONAL SAFETY AWARD 

Safer is Better 

Best Working Conditions 

for Aviation Research at ZAL 

— Protection and safety at work are mandatory – and in 

2019 it became official: ZAL excels in this duty. It was 

honored with the award for exemplary health protection 

and occupational safety in October. The Hamburg Office 

for Occupational Safety formally handed over the certificate 

to Roland Gerhards, CEO at ZAL GmbH, and André 

Kohlhoff, Head of Property Management at ZAL GmbH. 

The award was preceded by a thorough examination 

behind the scenes of ZAL. Auditors inspected the entire 

operational procedures in the hangars, laboratories and 

offices of ZAL TechCenter according to the concept of 

occupational safety (Ham burg Aufsichtskonzept ABS – 

Aufsicht, Beratung, Sys temüberwachung). As a result, all 

examined areas were seen to be at an exemplary level, 

and partly even exceeded the legal requirements. 

However, the office not only set their expert sights on 

the operation of the research center but also on the 

extra services for the employees at ZAL GmbH. The 

personnel working there benefit from a company health 

management system, such as flu vaccinations, thyroid 

gland examinations, vision tests, measures for old-age 

provision, flexitime, team events, subsidies for lunches 

and sports activities, and much more. As a result, the 

areas examined exceeded the legal requirements and 

received excellent ratings. 

ZAL was thus one of four Hamburg companies to 

achieve the highest category (Group 1) in the 2019 

awards. This clearly proves that the safety and welfare 

of all the building's users is a top priority for the company. 

›Safety is our duty, but well-being is an indispensable 

asset,‹ says Roland Gerhards, ›as innovations are 

only possible under best conditions.‹ 



VR TOUR 

68 — 69 

— Our new virtual reality tour of the ZAL TechCenter 

gives you an insight into the future of aviation. Learn 

more about our R&T topics, research partners, and 

infrastructures. And don't miss visiting us again! 

Gradually we will include more ZAL partners and 

new topics in our vr tour. 


vr.zal.aero


TECHNICAL FACILITIES 

The Invisible Impulse 

Technical Facilities for 

Aeronautical Research 

— 26,000 square meters for aeronautical research. The 

Safety is a top priority: the gas warning system detects a 

hangars, laboratories, and offices of ZAL TechCenter 

possible gas leak early. A gas management system works 

offer lots of infrastructures that make a researcher's 

to the highest technology standards to help precisely 

heart beat faster. There are test rigs, labs for fuel cell 

control the pressure and consumption. It automatically 

research, AI or acoustics, an entire park of 3D printers, 

notices the amount of consumption and the amount 

70 — 71 

and much more. But it is not just this accumulation of 

facilities that make the building a research center. More 

than that, it is the technical facilities behind the infrastructures 

that make the research possible in the first 

place. The ZAL TechCenter combines features that are 

technically more specific than in a hospital: from hangar 

spaces, which can handle weights up to ten metric tons 

per square meter, to laser technology, to the offering of 

gases, clean compressed air, and process cooling. 

remaining in storage. In this way, the ZAL property team 

can plan in advance and replace the gas pressure vessels 

in good time. Especially when it comes to research, it is 

important to guarantee the full availability of technical 

gases in the amount and quality needed at all times. 

UNDER PRESSURE 

With compressors, dryers, and filters, we elaborately 

generate high-purity compressed air at the ZAL. This is 

particularly required for the operation of fuel cells. 

GAS PANEL 

for technical gases. Part of the ZAL Fuel Cell Lab 


HIT THE GAS 

When it comes to 3D printing, too, it is used to cool the 

The basic equipment includes technical gases for tech- 

extruder; or in robotics, it moves the robots. The spe- 

nology processes. Fuel cell research, for instance, 

cial characteristic of this air is its high degree of purity. 

requires hydrogen and oxygen. Argon gas, in contrast, 

It is oil- and moisture-free, which means it isn't mixed 

shields metal against oxygen in 3D metal printing tech- 

with any fluids, oils, or dust. The purity is guaranteed. 

nology. All in all, researchers have access to nitrogen, 

oxygen, hydrogen, and argon. 

But how does the generation of compressed air work? 

Outside the building is a water-cooled compaction sys- 

The outdoor area, in the extension to hangar C, is where 

tem followed downstream by a filter and drying system. 

the gas storage warehouse is located. Here is where the 

This means the air is compressed, cleaned, and dried. A 

technical gases are safely stored in pressure vessels 

maximum of 17 cubic meters of pure air, at 10 bar, can 

and hooked up to the facilities. The gases go through 

thus be generated every minute. To achieve this same 

transfer stations, in which the pressure is controlled on 

high level, a person would have to operate 23,970 bicy- 

their way to the piping. This then guides the technical 

cle pumps simultaneously. The compressed air for pro- 

gases into the research laboratories and throughout 

cesses is provided exclusively to fuel cell testing sta- 

the hall spaces at ZAL. 

tions in the laboratories and in hangar C.



WARM-UP AND COOL DOWN 

Another topic of building technology is process cooling. 

The high-performance process cooling system is only 

It works like a refrigerator. The heat is removed, guided 

used for the cooling of technical systems. Without it, a 

COMPRESSED AIR SYSTEM 

for ZAL Fuel Cell Lab 

away, and released into the ambient air. Water, as an 

energy source, transports the heat away that the use of 

separate cooling system would have to be installed for 

each technical process that generates heat. To save 

the research facilities generates. By way of heat 

energy, the process cooling is adapted to the actual 

exchangers located at the research facilities, cold water 

consumption at all times. This means the pumps work 

takes on the excess energy and transports it through 

faster during high consumption and slower at low 

pipes. They lead up to the roof, where the evaporative 

consumption. 

coolers are situated. They feature an energy output of 

1,600 kilowatts. Depending on need, the heat is released 

Since the research center was opened, ZAL's property 

into the ambient air or transformed in line with the prin- 

team has optimized the building's technology efficiency. 

ciple of evaporative cooling. This is how it works: when 

In the case of process cooling, they have installed a 

the water vaporizes, it removes the heat from the object 

three-way valve featuring a bypass, to reduce the need 

it is on. At ZAL TechCenter, too, heat is removed through 

for evaporative cooling as much as possible. The three- 

evaporation. Water mist, generated with the use of high 

way valve regulates whether the water for cooling goes 

pressure, moistens the heated blades of the heat 

outside or by way of the bypass back into the building's 

exchanger. In turn, the heat evaporates away. 

water circuit. This happens when the water has not 

absorbed enough heat and ensures an energy-efficient 

system. Following the philosophy of getting the most 

72 — 73 

TECHNICAL BUILDING EQUIPMENT 

Refrigeration through compressed air and water systems 

with the least amount of effort. 




EVAPORATIVE COOLER 

of process cooling 

74 — 75 


SECONDARY CIRCULATION 

of process cooling 

THE INVISIBLE IMPULSE 

For the partners at the technology center the ZAL property 

team provides all the necessary equipment and 

aids for research. These mainly include the three 

above-mentioned systems for gas, compressed 

air, and process cooling. The fact that the technical facilities 

at ZAL are broadly based offers the best conditions 

for research, be it fuel cells, laser shock peening, or 

additive manufacturing.

76 — 77 

EVENTS 


Events

78 — 79 

EVENTS

ZAL EVENTS 

ZAL INNOVATION DAYS 2019 

ZAL Innovation Days 2019 

The Accelerator 

for Aviation Innovation 

EVENING EVENT 

A visionary keynote by Peter Haas, Associate Director of the 

Humanity Centered Robotics Initiative of Brown University, 

opened the exlusive evening event on board the MS KOI 

— Robotics & Advanced Automation was the topic of 

But there was more than just theory. Parallel workshops 

the ZAL Innovation Days in February 2019 at ZAL Tech- 

provided practical insights into relevant daily topics, while 

Center. Thomas Jarzombek, Coordinator of the Federal 

the permanent accompanying exhibition offered even 

Government for German Aerospace, supported our 

more practical demonstrations. Furthermore, Airbus and 

flagship event as patron: ›Aviation is the engine for 

XYREC presented a special highlight in one of the hangars: 

innovation, and events like the ZAL Innovation 

the prototype of a printing robot at work. A robot which 

Days are the accelerator‹, he declared. 

will revolutionize aircraft painting in the future. 

The conference program was divided into two topic 

An evening highlight for all participants was the gath- 

80 — 81 

blocks. While the first day focused on human-machine 

collaboration, day two put the spotlight on automated and 

autonomous systems. 

Industry leaders like Kuka, Festo, DFKI, and Siemens 

ering at the end of day one. The ZAL GmbH welcomed 

their guests on board the MS KOI – a top-class swimming 

event location! The exceptional atmosphere created 

by the illuminated port of Hamburg offered a great 

surrounding to make new contacts. 

KINOVA ROBOT IN ACTION 

During an interactive workshop the guests 

could test the robot arm themselves 

EVENTS 

reported on the potential of AI, robots, exoskeletons, and 

autonomous systems. And particularly interesting, they 

explained their increasing use in aviation. An industry 

in which manual workflows currently dominate both the 

assembly and painting of aircraft. 

WHAT DO ROBOTS MEAN FOR AVIATION? 

Roland Gerhards, CEO ZAL GmbH, and 

Thomas Jarzombek, Coordinator of the Federal 

Government for German Aerospace, discuss this 

topic together with Jens Gralfs, VP Research & 

Technology at Airbus



AN INSPIRING PROGRAM 

Keynotes, workshops, technical tours, and an 

exhibition provided insights into one of today's 

most relevant topics 

ROBOTS PRINTING ON AIRPLANES 

Peter Boeijink, CEO at XYREC, demonstrated the 

prototype of a printing robot together with Airbus 

82 — 83 

EVENTS 

AT A GLANCE – A SELECTION OF OUR TOP SPEAKERS 

Peter Haas, Associate Director at Humanity Cen- 

Prof. Dr. Wolfgang Wahlster, Director & CEO of 

Prof. Dr. Ellen Enkel, Professor at Zeppelin Univer- 

Dr. Adam Grzywaczewski, Deep Learning So- 

tered Robotics Initiative of Brown University, pre- 

DFKI, 1997–2019. In his keynote, Wahlster described 

sity, showed how collaborations between research 

lution Architect at NVIDIA Corporation, stated 

sented a comprehensive overview of the world 

the principles of autonomous production systems, 

and industry in research clusters help to create a 

that robots powered by AI will change the way 

of robots today and in the future. He referred to 

which go beyond current Industrie 4.0 technology in 

protective room to experiment, to open up, to devel- 

we work and live. AI makes it possible for robots 

human-machine interactions and automated & au- 

the aerospace industry. He showed that new tech- 

op trust and creativity. The result: unique innovation 

to perceive and interact with their environments 

tonomous systems and focused on the questions: 

nologies like deep learning, GPU-based automated 

outcomes. 

in novel ways, enabling them to take on unthink- 

What's possible with the help of robots on the 

production planning, and multimodal interfaces are 

able tasks, he said. There are endless opportuni- 

ground and in the air? When will a robot do your 

key success factors for aircraft production. Hybrid 

ties for robots to create new efficiencies and im- 

job? 

teams of cobots, softbots, and people are the basis 

prove quality of life through industries such as 

for the next generation of autonomous manufactur- 

manufacturing, logistics, healthcare, and service. 

ing in smart aerospace factories, he argued.



FORESIGHT 

The ZAL Innovation Days 2019 provided 

insights into the smart factory of tomorrow 

Zvi Feuer, CEO at Siemens Industry Software Ltd., 

Ryan Diver, Head of Technology for the Integrated 

referred to cobot systems and the areas of applica- 

Manufacturing Group at AMRC, gave a close insight on 

tions in the industry. He pointed out how the human- 

how new work collaborations provide incentives for 

84 — 85 

machine interaction can be influenced by cobots. 

Mona Stünckel, Lufthansa Technik & 3D-Aero, and 

successful research and development partnerships – 

especially in the field of robotics. 

EVENTS 

Michael Ernst, 3D-Aero, pointed out that the aviation 

Dr. Elsa Andrea Kirchner, Team Leader – Team Sus- 

MRO industry holds many potentials but also challeng- 

tained Interaction & Learning and Head of Brain & Behav- 

es for the areas of digitalization and automation. 

ioral Labs at DFKI Bremen, talked about future trends in 

robotics, especially on the need for AI and new approach- 

Thomas Schmidt, Key Account Manager of KUKA Systems 

GmbH, presented the possibilities of advanced 

automation in the aerospace assembly. Therefore, he 

es for human-machine interaction that enable robots to 

better understand and support humans. 

HUMAN-MACHINE INTERACTION 

Exoskeletons can support people 

in everyday life and work 

showed different KUKA Robotic Systems from a vi- 

Dr. Bob Struijk, Vice President Business Develop- 

sionary point of view. 

ment at FANUC, explained how robots can be used in 

the aerospace industry. He demonstrated the state 

Wolfgang Pomrehn, Bosch Rexroth AG, showed new 

of the art and discussed approaches for further re- 

possibilities that collaborative robots open up for 

search and development. 

flexible automation, and he presented the advantages 

and possibilities of safety fenceless automation. 

Prof. Dr. Norbert Elkmann, Head of Business Unit 

Robotic Systems of Fraunhofer IFF, described the 

Dr. Niko Reuss, Leader Advanced Product Technol- 

state of the art of assistive robots and human-cobot 

ogy at Festo, discussed Festo‘s agile development of 

collaboration. 

new robotic systems by the example of a pneumatic 

robot system. He showed the importance of collaboration 

and communication in networks.


LSP DAYS 2019 

LSP Days 2019 

ZAL Welcomes Laser Shock 

Peening′s International Elite 

— How can we increase the service life of components 

subject to cyclic stresses? How can laser shock peening 

representatives. To this end, the first day of the event 

was entirely dedicated to the physical fundamentals 

INTERNATIONAL EXPERTS 

The international laser shock peening elite 

met at ZAL and HZG for the LSP Days 2019 

be implemented in the most up-to-date manufacture of 

of Laser shock peening, a process in which short 

high-performance structures? 

laser pulses generate precise residual stresses within 

These and many other questions were the focus of the 

components. 

LSP Days, which ran in September 2019 in Hamburg and 

As the event progressed, world-class speakers such as 

Geesthacht. In cooperation with the Helmholtz-Zentrum 

Dr. Yuji Sano explained how Toshiba uses peening on 

86 — 87 

Geesthacht (HZG), the ZAL GmbH organized this year's 

international event series, presenting top-class lectures 

from various fields of science and industry. Participants 

nuclear reactor shells in Japan. Prof. Phil Irving from 

Cranfield University demonstrated how the fatigue 

properties of aircraft structures can be increased using 

EVENTS 

from over twelve countries were greatly impressed by 

laser shock peening. These and other practical applica- 

the topflight contributions, comprising lectures, inter- 

tions were also introduced to the participants at the 

active workshops, and an exhibition area about the 

workshops. During the two days the guests were able 

practical applications of this high-end technology. 

to see Europe's largest laser shock peening facility in 

The LSP Days 2019 aimed to bring scientists from uni- 

operation – the infrastructure of ZAL was inaugurated 

versities and research institutes together with industry 

one year earlier. 

From left to right: PROF. BENJAMIN KLUSEMANN Leuphana University, DR. BALTHASAR FISHER CEO XARION Laser Acoustic GmbH, DR. SERGEY CHUPAKHIN 

Senior Systems Engineer ZAL GmbH, DR. GORAN IVETIC Premium Aerotec, DR. DOMENICO FURFARI Airframe Technical Advisor Airbus, DR. DAVID OSMAN 

BUSSE Senior Systems Engineer ZAL GmbH, DR. DAVID LAHRMANN VP Business Development LSPT Technologies, PROF. ARIF. S. MALIK University of Texas 

Dallas, DR. YUJI SANO Program Manager at the Japanese Institute for Molecular Science, PROF. ULRICH KRUPP RWTH Aachen, PROF. JOSÉ L. OCAÑA 

Polytechnical University Madrid 

ZAL LSP INFRASTRUCTURE 

The guests were impressed by Europe's 

largest laser shock peening plant


ZAL SCIENCE SLAM 2019 

ZAL Science Slam 2019 

Smart Minds with a Sense of Humor 

— Once again, Hamburg's most humorous engineers, 

The last slammer of the evening, Thomas Kruse-Strack 

scientists, and a junior scientist were able to show what 

from Airbus, was voted the winner of Science Slam 

they are made of at ZAL's Science Slam. Like in the past, 

2019. With his highly entertaining pitch for CFRP adhe- 

the event enjoyed huge popularity. 

sive repairing, which is suspiciously similar to the dating 

phases between men and women, he was able to 

As usual, the order of the slams was determined via a 

win the audience over the most. His award: a lovingly 

random draw. And, as usual, each of the five slammers 

compiled gourmand package and, of course, a roaring 

88 — 89 

had ten minutes to perform their presentations. The 

exciting and funny talks were supported by a charming 

moderator and involved the audience, who served as 

applause. 

EVENTS 

the jury at the same time. 

A POPULAR EVENT 

High spirits prevailed at the get-together 

At the 3 RD SCIENCE SLAM, slammers from the 

Hamburg Aviation network competed against 

slammers from the ZAL TechCenter for the first time 

SMART AND FUNNY 

Hamburgs bravest engineers showed what 

they are made of at the Science Slam


ZAL OPEN LAB 

ZAL Open Lab 2019 

What Our Research & Technology 

Teams Can Do for You 

— In May, ZAL GmbH held an Open Lab Day for all those 

discussed with our 35 experts at hand the potential of 

interested in what goes on in the ZAL TechLabs. The 

the technologies presented and their possible applica- 

event was a great success. Numerous guests immersed 

tions and use. 

themselves in our multidisciplinary research topics 

Our Additive Manufacturing team used the event to 

such as Robotics, Additive Manufacturing, and Digital 

introduce their new laboratory and their new services 

Technologies. 

for p roject partners to the public. While the 3D printers 

Especially the live demonstrations of current technol- 

were printing in the background, they presented their 

90 — 91 

ogy projects were met with great interest, for example 

a 3D printing robot, a security vehicle, a fuel cell drone, 

or an AI program for image recognition. The visitors 

topics such as functional integration, hybrid manufacturing, 

fused filament fabrication with metal, and topology 

optimization. 

EVENTS 

3D PRINTING ROBOT 

Till Ludevig, robotics expert ZAL GmbH, 

presents one of the highlights in the ZAL TechLab 

OPEN DOORS 

at the ZAL TechLabs 

The experts at ZAL GmbH 

presented their infrastructure 

and research projects

92 — 93 

ZAL GMBH 2019


IMPRINT 

ZAL CENTER OF APPLIED 

AERONAUTICAL RESEARCH 

Hein-Sass-Weg 22 

21129 Hamburg 

Germany 

T +49-40-248-595-0 

F +49-40-248-595-111 

E info@zal.aero 

W www.zal.aero 

twitter.com/ZALTechCenter 

www.linkedin.com/company/zaltechcenter 

www.facebook.com/ZALTechCenter/ 

www.xing.com/companies/zalzentrumfürangewandteluftfahrtforschunggmbh 

zal.aero/newsletter 

foluhh@zal.aero – registration via e-mail only 

94 — 95 

IMPRINT 

PHOTO CREDITS 

Airbus Bockfilm 

Daniel Reinhardt 

EDITORIAL 

Lisa Becker, ZAL GmbH 

Miriam-Joana Flügger, ZAL GmbH 

CONCEPT & DESIGN 

Mjam Mjam Design, Hamburg 

mail@mjammjam.com 

www.mjammjam.com 

PRINT PRODUCTION 

Media Druckwerk, Hamburg 

mailbox@mediadruckwerk.de 

www.mediadruckwerk.de

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