ZAL-YB-021

ZAL Yearbook 

2021

Future. 

Created in Hamburg.

ZAL 

YEARBOOK 2021 

01 Introduction 

8 

10 

16 

Welcoming Address 

ZAL Highlights 2021 

Quotes 2021 

4 — 5 

02 Facts & Information 

ZAL GmbH – Business Areas 

20 Rental & Building Operation 

21 Partners 

22 Funded Research Projects 

26 Innovation Services 

27 Investments 

28 FoLuHH 

29 ZAL GmbH – Personnel

03 Innovation, R&T 

32 New Hydrogen Tank 

36 Emission-Free Flying 

40 Interview: Re-Structured ZAL Solutions 

44 Intelligent Digital Cabin – ZAL Endpoint 

48 ZALguard 

50 Robot-Guided 3D Printing 

04 ZAL TechCenter 

CONTENT 

56 ZAL Association 

60 Signage for Orientation 

05 ZAL Events 

66 ZALvirtual 

68 ZAL Innovation Talks 

69 Bigger, Better, Visionary – ZAL Expansion 

70 Digital TechWalk 

71 ZAL Science Slam 2021 

72 ITS World Congress 

73 Hamburg 1 Shooting 

76 Imprint

6 — 7

Introduction 

INTRODUCTION


WELCOMING ADDRESS 

Some Pioneering Steps 

to Take on the Crisis 

Dear Readers, 

8 — 9 

Aviation is taking on the crisis. And I am referring less to 

the ongoing pandemic than to global warming with its 

demand for climate-neutral flying. In 2021 we took 

some pioneering steps at ZAL to meet this challenge. 

The inauguration of the new hydrogen tank was a major 

milestone here. The new infrastructure expands the H2 

capacities at the ZAL TechCenter by a factor of 20. A 

prerequisite to meet the increasing research activities 

on this topic. Airbus, LHT, DLR, ZAL GmbH and other 

partners understand hydrogen to be a promising technology 

to decarbonize aviation. Read more about the 

expectations and pitfalls associated with the use of 

hydrogen in this yearbook. 

One other topic we are addressing is the ongoing digitalization 

of products and services in aviation. ZAL 

GmbH developed the ZAL Endpoint, a versatile cabin 

device, as a contribution to the Digital Cabin of Tomorrow. 

The ZAL Endpoint includes multiple software and 

hardware technologies allowing better performance, 

modularity, as well as weight and size reduction compared 

to current cabin electronics. Positive aspects 

that even serve sustainability. 

The same applies to our Additive Manufacturing project. 

On the one hand, it is about technology development for 

aircraft manufacturing, namely the cooperation of two 

3D printing robots. On the other hand, the project examines 

the use of recyclable materials in effective and 

resource-efficient processes, showing how weight can 

be reduced through function integration in a decentralized 

process with short delivery routes. 

An interview with our new team leaders illustrates how 

research work is organized at ZAL GmbH. Interdisciplinary 

teamwork, and fast implementation being our 

guiding principles. The development of the ZALguard is 

a good example of fast technical solutions at ZAL GmbH – 

in this case to simplify the short-term requirement of 

vaccination status control in our canteen. 

Another technical solution takes into account the developments 

in the event industry, namely the rising 

hybridization. The digital twin of the ZAL event areas is 

used by participants with the help of an avatar. The new 

tool enables the simultaneous attendance of on-site 

participants. Furthermore, we worked on continuous 

upgrades of the ZAL TechCenter. A new guidance system 

and wall design improve orientation in the research 

center and increase visibility for our tenants. In addition, 

DLR confirmed its intention for two of its institutes 

to become tenants of the ZAL extension, underlining its 

status as the second anchor tenant at ZAL. A multistory 

car park will meet the increasing demand for 

parking spaces in the future. Its construction began at 

the end of the year on the opposite side of the street. 

This is where the second ZAL extension is to be implemented 

as a new building. 

Enjoy reading about these and other topics. 

Yours, 

ROLAND GERHARDS

INTRODUCTION


HIGHLIGHTS 2021 

ZAL 2021 

Highlights 

10 — 11 

ZAL HYDROGEN TANK 

Introducing Michael Westhagemann, Hamburg's 

Senator for Economics and Innovation, to ZAL's new 

hydrogen tank and future research projects conducted 

by Airbus, DLR, Lufthansa Technik and ZAL GmbH. 

Read more: pp. 32–35

THE NEW SIGNAGE 

To ensure that tenants and guests can easily find their way 

around, ZAL implemented a refined wayfinding system. 

Read more: pp. 60–61 

INTRODUCTION 

ZAL MULTY-STORY CAR PARK 

The next step toward the ZAL expansion 

is done. The construction of the 

multy-story car park has begun.



12 — 13 

SUSTAINABLE AERO LAB 

In partnership with ZAL and Hamburg Aviation, the newly founded 

Sustainable Aero Lab will bring together relevant start-ups with 

investors, industry players and mentors from aviation, green 

technology and finance.

HAMBURG 1 SHOOTING 

TV magazine reported about 

research activites at ZAL. 

Read more: p. 73 

ZAL TRAINING 

ZAL experts shared their 

knowledge at two Heinze 

Academy courses on hydrogen 

and on methods for innovation. 

INTRODUCTION 

ZALVIRTUAL 

Participants of ZAL online events can 

get together as avatars at the digital 

ZAL TechCenter with the new event 

platform. Read more: pp. 66–67



ITS WORLD CONGRESS 

During the congress, ZAL hosted a technical visit, where 

participants learned more about ZAL's Open Innovation 

approach, current projects and the TechCenter. 

Read more: p. 72 

14 — 15 

ZALGUARD 

A small box for automatic 2G 

control. Read more: pp. 48–49 

ZAL DIGITAL TECHWALK 

ZAL opened its virtual doors for the second time 

for participants to explore the building and gain 

insights into the collaborative work here. 

Read more: p. 70

ZAL INNOVATION TALK HIGHLIGHT 

Grazia Vittadini, at that time Airbus CTO, spoke 

about green aviation, diversity and other exciting 

topics at the ZAL Innovation Talk ›Green Aviation 

5 Years From Now.‹ Read more: p. 68 

ZAL SCIENCE SLAM 

Once again, this time virtual and live, six bold 

engineers showed their reasearch topics in a 

humorous way. Read more: p. 71 

INTRODUCTION


QUOTES 2021 

» ZAL in Hamburg has 

increased the available 

hydrogen capacities by 

a factor of twenty. « 

AIRLINERS.DE 

16 — 17 

» Broetje-Automation has delivered 

its 250th EcoPositioner to the ZAL. « 

AERO-MAG.COM 

» 11th proTechnicale class takes off at ZAL TechCenter. « 

PRESSEBOX.DE 

» With ZAL, Hamburg has [...] a globally 

visible beacon for research & development, 

which is set to grow significantly again in 

the coming years. « 

SENATOR WESTHAGEMANN

» LHT, ZAL, DLR and Hamburg Airport 

have joined forces to advance the use 

of hydrogen as a future energy carrier 

for aircraft. « 

AEROBUZZ.DE 

» Hamburg Aviation and ZAL participate as associated 

partners in the project Sustainable Aero Lab. « 

DIE WELT 

» New highlight in the 

research halls: 20-meterhigh 

tank for hydrogen 

aircraft. « 

INTRODUCTION 

BILD HAMBURG 

» A320 Hydrogen Aviation Lab: ZAL participates with 

its know-how in the field of fuel cell technology and 

its digital process mapping. « 

MONEYCAB.DE

18 — 19 

Facts & Information

FACTS & INFORMATION

ZAL GMBH BUSINESS AREAS 

RENTAL & BUILDING OPERATION 

25% RESEARCH INSTITUTES 

22% OEMS, SUPPLIERS 

20 — 21 


TechCenter 

25% INNOVATION PARTNERS 

28% TECHNOLOGY PARTNERS 

— ZAL offers 600 workplaces for 23 partners. The latter consist of 22 percent OEMs and suppliers, 25 percent 

research institutes, 25 percent innovation partners, and 28 percent technology partners.

ZAL TECHCENTER 

PARTNERS 

AES 

AMPOWER 

AIRBUS 

CAPGEMINI 

ENGINEERING 

FFT 

DASSAULT 

SYSTEMES 

DIEHL 

AVIATION 

DLR 

FRAUNHOFER 

LIEBHERR 

HAW 

LSPT 

HELMUT 

SCHMIDT 

UNIVERSITÄT 

LUFTHANSA 

TECHNIK 

INDUSTRIAL 

DESIGN 

STUDIO 

PREMIUM 

AEROTEC 

FACTS & INFORMATION 

PRO 

TECHNICALE 

SFS INTEC SIEMENS SYNERGETICON 

TUHH 


GMBH 


ASSOCIATION


FUNDED RESEARCH PROJECTS 

Funded Research 

Projects 

Acoustics & Vibration 

22 — 23 

ANKA 

Autonomous sustainable aircraft cabin 

PARTNERS: Airbus, Diehl, TUHH PKT, ZAL GmbH 

FUNDINGS: LuFo VI/1 

DURATION: 10/20–12/23 

ILAD 

Integrated vibration attenuators 

PARTNERS: Elbe Flugzeugwerke, ZAL GmbH 


DURATOIN: 03/21–04/22 

UHBR2Noise 

Objective methods for measuring the vibration transmission of economy class seats 

PARTNERS: Airbus, University Oldenburg, ZAL GmbH 

FUNDINGS: LuFo V/3 

DURATION: 04/19–03/22 

Additive Manufacturing 

AMProSint 

Facility and material development for resource efficient production of metal structures 

PARTNERS: Element 22, Fraunhofer IAPT, Kreyenberg, MUT Advanced Heating, ZAL GmbH 

FUNDINGS: KMU-innovativ 

DURATION: 03/21–02/23

HUTAB 

Robot-guided additive manufacturing for hybrid production of aircraft parts on 

existing components 

PARTNERS: Cotesa, Diehl, HSU IfA, ZAL GmbH 


DURATION: 01/18–9/22 

LiBio 

Lightweight bionic aircraft interior 

PARTNERS: Aerospace & Advanced Composites, Antemo, Bombardier, F/List, 

Fraunhofer IFAM, FusiA, Inocon, Joanneum, Queen's University, Rembrandtin Lack, 

Solexis, SinusPro, ZAL GmbH 


DURATION: 03/20–02/23 

RAFINESS 

Robot-guided additive manufacturing of integrated, sustainable and electric conductive 

brackets for cabin sandwich structures 

PARTNERS: Fraunhofer IFAM, Fraunhofer UMSICHT, SFS Intech, ZAL GmbH 


DURATION: 09/21–08/23 


Automation & Robotics 

AIARA Artificial intelligence-enabled highly adaptive robots for aerospace industry 4.0 

PARTNERS: Broetje Automation, DLR ZLP BT, Element AI, Fraunhofer IPT, Kinova, UBC, ZAL GmbH 


DURATION: 04/20–03/23 

ADAPT 

Automated data link from design to production 

PARTNERS: Airbus, DLR SL, Dassault Systèmes, HSU IfA, Synergeticon, TUHH IFPT & ITL, 

ZAL GmbH 


DURATION: 07/20–06/23 

EFFEKT 

Connected technologies and systems for efficient aircraft cabins 

PARTNERS: Airbus, Aqua free, Diehl, DLR FA & LS, Osram, Tesa, TUHH IFPT & PKT, 

University Erlangen-Nuremberg FAPS, ZAL GmbH 


DURATION: 04/20–03/23


FUNDED RESEARCH PROJECTS 

Automation & Robotics 

MEDIFLY 2 

VLOS drone-based laboratory sample transport 

PARTNERS: BWVI, Flynex, GLVI, Hamburg Aviation, LIHH, Lufthansa Technik, ZAL GmbH 

FUNDINGS: mFUND 

DURATION: 09/20–09/22 

VeriKAS 

Explainable AI for drones 

PARTNERS: Hamburger Informatik Technologie-Center, hs2 engineering, 

Hamburg University, ZAL GmbH 


DURATION: 06/21–05/24 

24 — 25 

Fuel Cell & Electrical Power Systems 

Hydrogen 

Exploring liquid hydrogen systems for aviation 

Aviation Lab PARTNERS: DLR ITT & MRO & RA & SL, Lufthansa Technik 

FUNDINGS: HH-Taskforce IFB Hamburg, ZAL GmbH 

DURATION: 07/21–04/22 

GetPower2 Operational and safety aspects of an energy trolley 2 

PARTNERS: Airbus, Diehl, DLR ITT, Fraunhofer ICT-IMM, TUHH FST, ZAL GmbH 


DURATION: 04/19–12/22 

RTAPHM 

Development of a service broker technology for drone-based business 

models and data analytics to optimize fleet availability 

PARTNERS: Airbus, Avienco, Fortiss, Linova, TU Darmstadt, TUHH, 

TU Ilmenau, ZAL GmbH 


DURATION: 07/19–12/22 

BETA 

Fuel cell system development for aviation 

PARTNERS: Airbus, DLR ITT, HSU, ZAL GmbH 

FUNDINGS: NIP/NOW 

DURATION: 10/20–03/24

Intelligent Digital Cabin 

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 ComNets, ZAL GmbH 


DURATION: 08/18–07/22 

DELIA 

VERDIKA 

Distributed, extendable, lightweight, open, reliable, service-oriented 

architecture for next-gen mobility 

PARTNERS: AED, Hamburg University, Soletrix, University Stuttgart, ZAL GmbH 

FUNDINGS: KMU-innovativ 

DURATION: 02/19–01/22 

Connected digital cabin 

PARTNERS: Airbus, Diehl, DLR SL, SAFRAN, TUHH FKS & IFPT & PKT, ZAL GmbH 


DURATION: 01/20–03/23 


Laser Shock Peening 

LeadPeen 

Intelligent, fast and flexible laser peen forming process for complex 

shaped aircraft components and sheet metal parts 

PARTNERS: Lufthansa Technik, ZAL GmbH 


DURATION: 06/21–05/24 

PEENCOR 

Development and demonstration of an automated forming and straightening 

method using laser peen forming 

PARTNERS: Formtech, Helmholtz-Zentrum hereon, Luneburg University, 

ZAL GmbH 


DURATION: 05/20–04/23


INNOVATION SERVICES 

€ 4,000,000 

€ 3,500,000 

€ 3,000,000 

€ 2,500,000 

€ 2,000,000 

26 — 27 

€ 1,500,000 

€ 1,000,000 

€ 500,000 

€ 0 

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 

EARNINGS from funded research projects 

TOTAL 

REVENUES from industrial projects 

— 2021 was the first full year since the reorganization of the technical domains of ZAL GmbH. Despite the ongoing 

pandemic, important new client relationships were established and existing ones strengthened. Together, revenue 

from industry orders and income from funded research projects increased by 823,000 euros to 3,916,000 euros, an 

all-time high.


INVESTMENTS 

€ 20,000,000 

€ 15,000,000 

€ 10,000,000 

€ 5,000,000 


€ 0 

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 

INVESTMENTS/YEAR 

TOTAL INVESTMENTS 

— In the 2021 financial year, ZAL GmbH realized an investment volume of 719,517 euros. The main investment in 2021 

was the expansion of the infrastructure in the area of the Fuel Cell Lab. The construction of a stationary hydrogen 

storage facility with a usable capacity of over 300 kg and additional tapping points for higher outputs (up to approx. 

600 kW electrical output) was completed and handed over to the users in summer 2021.


FOLUHH – AVIATION RESEARCH NETWORK HAMBURG 

Content-Related Events 

ZAL INNOVATION TALK 

Interviews with well-known experts on future developments in aviation 

ZAL DISCOURSE 

Expert speakers, panel discussions and conversation 

ZAL TECHWALK 

Experts demonstrating their projects at ZAL TechCenter 

SCIENCE SLAM 

Scientists presenting their own research work in a given timeframe 

in an entertaining way 

28 — 29 

Networking Events 

ZAL MANAGEMENT BREAKFAST 

Networking at management level 

ZAL DIGITAL MEETUPS 

Casual gatherings in homely atmosphere 

ZAL LUNCH CONNECTION 

Eating, meeting and getting to know each other 

— The Aviation Research Network, abbreviated in German as FoLuHH, is connecting the aviation community and 

promoting innovation through a variety of activities and events. Therefore, it engages in topics such as product and 

process innovation, prototypes, topic-related networking, and public relations work. Furthermore, FoLuHH provides 

a platform for interdisciplinary exchanges and collaboration between scientific and economic partners, such as 

technology and innovation experts, research institutes, OEMs, and suppliers.

ZAL GMBH 

PERSONNEL 

2020 

57 


GMBH 

2021 

58 


11 FEMALE & 

47 MALE EMPLOYEES 

— The number of employees remained almost constant at 58 as of December 31, 2021, despite the increased 

order volume.

30 — 31

Innovation, R&T 

INNOVATION, R&T

INNOVATION, R&T 

NEW HYDROGEN TANK 

New Hydrogen Tank at ZAL 

Flying Green Tomorrow 

— Since August 2021 the vision of emission-free flying has become a bit more of a reality 

in Hamburg. The ZAL Center of Applied Aeronautical Research has expanded its hydrogen 

infrastructure with a 20-meter-high, 100 m³ tank. The tank increases the capacities 

available at the research center twentyfold. 

32 — 33 

The timing couldn't be better as the aviation industry 

currently faces major challenges: on the one hand, it 

needs to survive the crisis brought about by the pandemic, 

while on the other hand – and at the same time – 

it must strive to make the future of flying emission free 

in order to protect the environment. The scientific and 

technical steps needed for this are being developed at 

ZAL TechCenter. 

ZAL has been active in the field of hydrogen since 2009. 

ZAL GmbH operates the Fuel Cell Lab, rents out fuel cell 

laboratories, and offers consulting, development, and 

testing services in the field of fuel cell technology. The 

Fuel Cell Lab is a cross-sector research laboratory, both 

for aviation and other mobility applications. A total of 

approx. 3.7 million euros has been invested in the lab 

infrastructure since 2015. The 20-meter-high hydrogen 

tank from the company Air Products, which has now 

been put into operation, expands the possible test 

capacities on site by a factor of 20. The 100 m³ storage 

tank keeps around 400 kg of hydrogen on site. The 

hydrogen is delivered from the Air Products plant in 

Stade, 30 km away. 

ZAL's focus is on the integration of fuel cell technologies. 

To achieve this, a total of 11 laboratories for fuel cell 

technology research are available. Here, researchers 

work on the development of these technologies, the 

design of fuel cell systems for various applications like 

emergency power supply or power trains, and the analysis 

of the required hydrogen infrastructures with the 

main focus on aerospace. Besides theoretical work 

based on systems engineering as well as modelling and 

simulation (digital twins), the assumptions are verified 

and validated by lab tests. The Fuel Cell Lab is ideally 

equipped for this, it grants a secure supply of hydrogen, 

oxygen, and nitrogen from pressure vessels and provides 

oil-free compressed air. In addition, a several 100 

kW cooling loop can be used to dispose the heat produced 

by the fuel cell reaction, while an air extraction 

system for up to 1,800 m³/h per test bench in combina-

tion with dedicated hydrogen waste lines ensure the lab 

safety. Some test stands are placed in the hangars to 

have access to complete aircraft segments as well as 

have the opportunity to run fuel cell systems with electrical 

output of about 600 kW. Usually, more complex 

tests are performed in the laboratories that are related 

to the behavior of the fuel cell stacks in case of cold temperatures 

or changed oxygen provision conditions (like 

thinner air at flight level of aircrafts). A special feature of 

the Fuel Cell Lab is that any surplus energy generated 

can be fed back into the Hamburg power grid up to 

640 kWel as environmentally friendly energy recovery. 


F.L.T.R.: ROLAND GERHARDS, CEO ZAL GmbH; MICHAEL WESTHAGEMANN, Hamburg's Senator for Economics and Innovation; NICOLE DREYER-LANGLET, Vice 

President Research & Technology Representative Germany, Airbus; DR. CHRISTOPH DE BEER, Head of Political Affairs, Lufthansa Technik; DR. THOMAS ZILL, Vice 

Director Institute of System Architectures in Aeronautics, DLR; NAWINA WALKER, Head of Operational Site Management Hamburg & External Affairs, Airbus


NEW HYDROGEN TANK 

»Hydrogen is the future. And the inauguration of the new tank architecture at ZAL 

is one of the pillars we need in the transformation towards green flying. The new 

hydrogen storage tank shows that Hamburg as an aviation center is moving towards 

sustainability and zero emissions by investing in concrete projects and measures.« 

MICHAEL WESTHAGEMANN, Senator for Economics and Innovation, Hamburg 

34 — 35 

DR. JÖRG TAPPERMANN, Head of Fuel Cell Systems, 

Airbus, introducing current hydrogen projects of Airbus 

»Hydrogen technology plays a key role for Airbus as is illustrated by our ZEROe concept 

aircraft, for example. However, the future utilization of this forward-looking energy 

source in commercial aviation is a team effort and can only succeed if we work together. 

We are therefore very pleased that the Hamburg region is taking the lead here in close 

cooperation with the political, scientific, and economic spheres. ZAL and its research 

infrastructure are an indispensable platform for developing the necessary technologies. 

We look forward to expanding this cooperation.« 

DR. ANDRÉ WALTER, Chairman of the Board of Management of Airbus Commercial in Germany and Head of the Hamburg site

»Lufthansa Technik is a founding member, shareholder and therefore a part of ZAL. We are 

excited about the expansion of the hydrogen infrastructure, which will enable the development 

of pre-competitive technology expertise. Together with our new field laboratory for 

ground and maintenance processes in aviation, we will then have outstanding opportunities 

to take research into hydrogen as a future source of energy for aviation to a new level.« 

DAVID DOYLE, Vice President Corporate Strategy, Business Development and Innovation Management at Lufthansa Technik 

»The ZAL partnership network and the infrastructures 

provided offer an ideal environment for researching 

revolutionary technologies such as hydrogen-powered 

engines for climate-neutral flying. Experiments on real 

aircraft components and digital mapping methods go 

hand in hand. This will jointly optimize the design and 

manufacture of future aircraft. In a next step, we are 

looking forward to also designing and testing the 

ground and maintenance processes for hydrogen 

aircraft not only digitally but, in collaboration with 

Lufthansa Technik and ZAL GmbH, also on a converted 

A320 stationary demonstrator at Hamburg Airport.« 

INNOVATION, R& T 

DR. BJÖRN NAGEL, Founding Director DLR Institute of System Architectures in Aeronautics 

H 2 

INSIGHTS 

Dr. Sebastian Altmann (left), Hydrogen 

Expert ZAL GmbH, explains technical 

details of the new tank

36 — 37


EMISSION-FREE FLYING 

Emission-Free Flying 

The Significance of Hydrogen 

for the Aviation Industry 

— It is the big question for the aviation industry: how can global air traffic be made 

emission-free in the future in view of the consequences of climate change? And the 

big question for ZAL – what might be the role of the research center in this? 

These days it is becoming apparent in sectors such as 

the automotive industry that battery electric driving 

will probably prevail in the mass market for passenger 

cars. In aviation, however, it is more likely to come 

down to a ›solution mix‹. For the foreseeable future, 

aviation will only be able to follow the path of the car 

in the absolute short-range segment; batteries are 

too heavy, and too large for large-scale use in the 

third dimension. Another measure is the large-scale 

use of Sustainable Aviation Fuels, abbreviated SAF, 

i.e. synthetically produced kerosene. SAF may be an 

important interim solution, but it will not lead to the 

goal of flying completely emission-free. Moreover, 

production capacities for this technology are currently 

still too marginal, and the primary energy 

requirement from ›green‹ sources is far too high in 

the long term. 

Hydrogen in aviation is anything but new: as early as in 

the 1930s, hydrogen-filled zeppelins were flying across 

the Atlantic. In the final years of Soviet aircraft construction, 

Tupolev converted a Tu-154 to hydrogen power, 

which then successfully completed numerous flight tests 

as the Tu-155. In the EU, research on the ›Cryoplane‹ was 

carried out in the 1990s in a consortium with Airbus. 

Hydrogen has thus been a topic in the aviation industry 

for a long time. And here at ZAL, too, we have been mapping 

the entire R&D process chain, consulting and testing 

out feasibility studies as well as customized prototypes 

since the Fuel Cell Lab opened in 2016. So given 

the current emissions issue, what's stopping us from 

getting on a hydrogen-powered commercial aircraft 

tomorrow? Well, in addition to the advantages already 

mentioned above, the element brings with it two crucial 

issues. 


There remains another great source of hope, which has 

been researched at ZAL for some time, and is currently 

the focus of particular attention in Europe: hydrogen. 

Indeed, hydrogen has some decisive advantages for 

aviation: it is characterized by a very high gravimetric 

energy density, is extremely light – in contrast to batteries 

of any kind – and, like kerosene, can be transported 

well over long distances and stored for long periods 

without losses. 

Liquid hydrogen in commercial aircraft 

Hydrogen may have a big weight advantage, but the 

catch is its very large volume. As a gaseous fuel, this 

makes it inefficient for flight operations. The space 

required for tanks in the aircraft would be too large. 

Liquid hydrogen would be much more suitable as a 

fuel because of its density, which is almost 1,000 times 

higher, but the element's boiling point is -253 °C. 

Numerous new technological ›bricks‹ must therefore


EMISSION-FREE FLYING 

38 — 39 

be developed in order to fly with liquid hydrogen. 

These include not only appropriate tanks including 

insulation, piping and valves, but also all components 

related to thermal management to ensure that the 

maximum temperature of -253 °C is maintained under 

all conditions, but at the same time that sufficient 

hydrogen is available for operation. 

The question of the drive module is also crucial: the 

obvious solution would be to convert an appropriate 

gas turbine, as already exists today. Although this would 

be CO 2 

-free if regeneratively produced hydrogen were 

used, combustion by-products such as NOx would be 

generated for technical reasons. A further development 

step that would also solve this problem, but would also 

involve further development of the aircraft design, 

would be the use of fuel cells with downstream electric 

motors. A topic that is researched by the Stuttgart company 

H2FLY with Prof. Kallo, among others, and where a 

flying demonstrator already exists. In the UK, the startup 

ZeroAvia is currently the most prominent player in 

this field, converting a Dornier 228 for its purposes. 

Airbus has also been focusing entirely on hydrogen propulsion 

since 2020 with its ›ZEROe‹ strategy, but the 

range of concepts presented – from turboprops to 

blended-wing bodies – currently leaves all doors open 

for technological design. Research on this is in full swing 

at ZAL. 

Another advantage of the fuel cell in theory is that its use 

would reduce the formation of condensation trails, and 

thus their impact on the climate. Unlike jet engines, however, 

the waste heat from fuel cells cannot simply be 

discharged via combustion gases. This would require, for 

example, the development of new types of heat exchangers 

that would not have such a negative impact on the 

weight and drag of the aircraft. 

Sustainable value chain for sustainable hydrogen 

Today's standardized fuel has one major advantage: it is 

available at almost every airport in the world, and can be 

refueled using standardized nozzles. For hydrogen, on 

the other hand, this infrastructure would first have to be 

created from scratch. While the EU is already considering 

which existing natural gas pipelines could be used for 

this purpose in the future, Paul Eremenko, ex-CTO of 

Airbus and United Technologies, and his Californian 

start-up Universal Hydrogen are trying a ›hack‹: similar to 

Nespresso capsules. The company wants to offer a retrofit 

system for H 2 

-filled cartridges that can simply be 

loaded onto the aircraft on the ground and exchanged at 

every stop. 

However, much more decisive – similar to SAF – is the 

question of how hydrogen could be produced at all in the 

quantities required for aviation. Only ›green‹ hydrogen, 

i.e. hydrogen produced entirely by means of renewable 

energies such as sun and wind, would even be considered 

for this purpose. This green hydrogen will be of 

great interest to many industries, since it seems to be the 

only way to meet the CO 2 

targets. For aviation, therefore, 

there is a particular motivation to consume as little as 

possible. Complex technologies, and new materials for 

reducing consumption, such as active laminarization, are 

likely to become even more relevant in this context. 

The challenges to be overcome for hydrogen-powered 

aviation thus remain high. All the more reason to promote 

fresh ideas and visions, for example with the Sustainable 

Aero Lab – a hotbed for sustainable aviation 

start-ups. As ZAL, we are then very powerful in later 

stages when it comes to application and integration into 

the aircraft. ZAL will not invent the hydrogen aircraft, but 

will certainly bring together the components and partners 

for it so that it can take off later.

HYDROGEN 

is an essential building block for the success of emissionfree 

mobility. This also applies to aviation: converted into 

electricity for electric motors or as fuel, the use of hydrogen 

reduces harmful emissions to a minimum 

INNOVATION, R&T


INTERVIEW 

Fast, Green and Interdisciplinary 

Re-Structured ZAL Solutions 

40 — 41 

— To prepare the company for the upcoming technical and environmental challenges, the 

technology division of ZAL GmbH has recently undergone a transformation. The internal 

reorganization was accompanied by the retirement of the former Head of R&T, Dr. Robby 

Technow. He had played a key role in shaping the division. His retirement in 2021 represented 

the right time to take the organizational structure of the technology teams that had grown 

under him to the next level. 

F.L.T.R.: Dr. Thorsten Scharowsky, Head of Advanced Materials; Mark Etzold, Head of Automation; 

Dr. Leonid Lichtenstein, Head of Data & Power Networks; Dr. Christoph Heß, Chief Strategy Officer

After five years of ZAL TechCenter, the technology division 

of ZAL GmbH comprises no fewer than seven specialist 

disciplines, including: Robotics & Automation, Industrial AI, 

Additive Manufacturing, Laser Shock Peening, Acoustics & 

Vibration, Fuel Cell Systems and Intelligent Digital Cabin. 

The new organization now clusters these activities in three 

technical domains. The specialist areas with their 40 

employees are being managed by three team leaders, their 

deputies as well as a strategy manager, who is responsible 

for the overall strategy and business development. Even 

though the reorganization was primarily carried out as an 

internal process, its benefits are visible externally. 

Q: For external partners, what changes does the internal 

reorganization of the technology division entail? 

Thorsten: And the advantage of it is that the speed of 

implementation does not apply solely to individual specialist 

areas but across the board. We are deeply rooted 

in the individual topics, but at the same time are in close 

coordination with each other. This allows us to fully 

exploit our typical ZAL potential for interdisciplinary 

technology solutions. 

Leonid: We consider ourselves a technological speedboat 

for aviation research. We are agile and able to get 

things done quickly. The new structure has further 

strengthened this aspect. With our three management 

duos, we can ensure the diversity of topics, not only in 

terms of breadth, but also in terms of depth. This is a 

great advantage in contact with customers and partners. 

On the one hand, we understand their technical challenges, 

on the other hand, we can make quick decisions 

internally and promptly work on solutions. 

Mark: I completely agree. In fact, we have short and efficient 

coordination processes. It is common for a partner's 

inquiry to be followed by an implementation project 

– for example, a feasibility study or the realization of 

a prototype for pre-development. 

Q: Can you describe what such ZAL-typical 

interdisciplinary solutions look like in practice? 

Leonid: For example, on behalf of Airbus, we have conducted 

a concept study for a hydrogen-powered AGV, 

Automated Guided Vehicle, with a payload of 30 tons, 

and a size of approximately 7 m x 3 m for aircraft production. 

After analyzing the customer's requirements for the 

system, we designed an initial system that would provide 

the required performance and not exceed the available 

installation space. The close cooperation between our 

robotics and fuel cell research teams was the game-winning 

factor. 

Mark: While the automation experts took care of the 

sensor technology and the robotics experts of the AGV, 

our H 2 

colleagues ensured the integration of a hydrogenpowered 

fuel cell system. Conventionally, the AGV is 

powered by a diesel-electric hydraulic drive train. The 

advantages of an operation with a fuel cell are, in addition 

to the aspect of environmental friendliness, a significant 

increase in efficiency and potentially a reduced 

maintenance effort. 

INNOVATION, R&T


INTERVIEW 

42 — 43 

Q: Currently, society and politics are demanding 

that aviation reduces emissions to a minimum. 

What does ZAL contribute to this? 

Christoph: Quite simple, we develop technical solutions. 

The vision of emission-free air traffic is clear, challenging 

and big. But the way to get there must be taken 

in many small steps. Many of our current projects are 

exemplary in this respect. Existing system solutions 

must be checked for sustainability and optimized, but 

new system solutions must also be introduced and made 

suitable for aviation. Take the example of fuel cell technology. 

Using green hydrogen, fuel cell technology is a 

climate-friendly possibility of generating energy. Its 

potential for aviation has long been recognized. However, 

the numerous challenges associated with the integration 

of this technology into an aircraft are also well 

known. And here we say: one thing at a time. Give us a 

technical problem and we'll solve it. Fuel cell systems, for 

example, are a complex system consisting of many individual 

parts – the current weight of which leads to problems 

in aircraft integration. 

Thorsten: We have developed a solution to approach 

this problem in the ALF project (Additive Manufacturing 

Lightweight Fuel Cell – funded by the Federal Ministry for 

Economic Affairs and Energy based on the resolution of 

the German Bundestag), a research project about the 

development of lightweight fuel cell stacks. We combined 

our internal expertise on the design and operation of 

fuel cell stacks with our expertise on additive manufacturing 

processes, assembly and components. This way, 

we managed to find a way to make the stacks lighter. By 

implementing a new design, new materials and a new 

process route, we are now saving up to 50 percent of the 

weight in the end plates. We do this by replacing the conventionally 

used end plates with additively manufactured 

plates. Furthermore, the hybrid design of additive manufacturing 

enables us to functionally integrate various 

important properties such as mechanical stability, gas 

tightness, insulating properties as well as electrical connection. 

In total, this approach allows maximum weight 

savings and optimal functionality at the same time. 

Q: What role does sustainability play in research 

areas beyond fuel cell activities? 

Christoph: In general, the topic of sustainability is considered 

in all research projects. The question is rather, 

where is the respective tipping point in a project? You 

must take into consideration that most CO 2 

emissions 

occur during aircraft operation. Therefore, lightweight 

construction comes first. Nevertheless, the use of recyclable 

materials is immensely important to achieve a circular 

economy and become truly sustainable. In other 

words: we consider sustainability seriously and implement 

it where it makes sense.

obotic arm. The idea is for the robotic system to print a 

bracket onto an existing cabin component, which simultaneously 

contains conductors for the electrical connections. 

Thus, we are able to streamline the assembly 

processes. 

Q: How does ZAL ensure that it will innovate 

in the future? 

Thorsten: In one of our our current projects we are testing 

the use of a new, sustainable polymer for utilization 

in aircraft cabins with our Additive Manufacturing team. 

The focus here is on brackets, small components that 

serve as an interface between the fuselage structure of 

the aircraft and cabin components. Until now, brackets 

have consisted of a variety of materials making recycling 

difficult. Most of the plastic parts of the bracket are 

based on plastics of fossil origin. Therefore, the project 

aims to develop a sustainable material for manufacturing 

the brackets. The described goal is a polymer material 

with a CO 2 

footprint reduced by about 30 percent compared 

to previously used polymer materials. To be honest 

though, the recycling aspect is just a side goal of the 

project. 

Mark: Indeed, the focus is on something else here: 

installing brackets on cabin components is a very smallstepped 

process, some of which is done by hand, consisting 

of preparing the cabin component, bonding the 

bracket, finishing the bracket, installing the cabin component 

in the cabin and finally wiring the component. 

The goal of my project team is to combine this smallstepped 

process into one procedure. Currently, we are 

working across teams on a solution using our 3D printing 

Leonid: As described earlier, we ensure innovative processes, 

prototypes and products through our interdisciplinary 

cooperation. Because innovative solutions can 

only be developed by linking different technologies, and 

in this respect, we have highly motivated employees with 

a ›can-do‹ mindset. This provides a wide range of options, 

and we can quickly try things out and build and validate 

them in our labs. For example, linking digital solutions 

with production processes or diagnostic capabilities of 

complex systems allows for an optimal utilization of 

financial and material resources. And these are becoming 

increasingly important, especially in the discussion 

about sustainable solutions. 

In addition, we have the shortest conceivable paths to 

exchange and realize innovative solutions with our partners 

and customers under one roof. 

Christoph: Furthermore, we work according to wellestablished 

methods in our projects. We have an internal 

Innovation Accelerator team that supports our work by 

applying agile methods and carrying out all development 

steps according to the so-called fail-fast principle. In 

addition to this, our large network of technical aviation 

expertise at ZAL allows us to evaluate potential innovations, 

for example according to technical feasibility or 

industrial relevance. All this has a positive effect on the 

speed of innovation processes as well as the successful 

realization of new ideas in general. 

INNOVATION, R&T


INTELLIGENT DIGITAL CABIN 

Intelligent Digital Cabin 

ZAL Endpoint Digitalizes 

Aircraft Cabins 

— The future is digital. In aviation research, this is especially true for the aircraft cabin. 

Technological innovations and digitalization will ensure a smooth and seamless passenger 

experience in the future: from in-flight entertainment to mood lighting in the cabin. To this 

end, engineers in the InDiCa department, which stands for Intelligent Digital Cabin, are 

constantly developing communication technologies and innovative systems. 

44 — 45 

ZAL ENDPOINT 

Cornelia Brülhart, ZAL Expert Distributed Systems & 

IT-Security, loading the pick-and-place machine

THE ZAL ENDPOINT 

is a versatile next-generation aircraft cabin 

device that combines several sub-technologies 


Within ZAL GmbH, a research team is working at the 

forefront of digital cabin technology. It implements projects 

on use cases within the cabin, such as innovative 

cabin lighting, cameras in combination with AI or novel 

sensor technology. This is done based on embedded 

and distributed systems, wireless and wired communication 

networks and new technologies for sensors and 

actuators. In this context, the in-house development of 

embedded hardware and software is essential, which 

ZAL GmbH also offers to customers as a highly flexible 

and individualized service. 

All devices within the network, from the backbone to the 

end devices, will be able to communicate via standardized 

protocols based on the Internet Protocol (IP). This means 

that in the future, all communication in the cabin will be 

handled via an IP-based network. 

The ZAL Endpoint 

The Intelligent Digital Cabin is a conglomerate of individual 

solutions that are interlinked. One of these is the ZAL Endpoint, 

a versatile next-generation aircraft cabin device. It 

combines several sub-technologies. 

The cabin network in aircraft supplies all functions in the 

cabin. This includes reading lights, air conditioning, loudspeakers, 

monitors, crew interphone and much more. Current 

cabin networks consist of numerous devices, often 

interconnected via various proprietary communication 

links. It is envisioned that future cabin networks will be unified 

into ›all IP‹ solutions based on Ethernet connections. 

One of these technologies is the Single-Pair Ethernet 

(SPE). With its reduced cabling complexity, SPE is a promising 

candidate for connecting endpoints to a multi-gigabit 

backbone in the cabin. SPE requires only two cable cores: 

a twisted pair, for speeds up to one billion of bits per second. 

By comparison, conventional Ethernet, as we know it 

from home, requires eight cable cores, i.e. four twisted


INTELLIGENT DIGITAL CABIN 

pairs. In aircraft, SPE can thus save costs because the cables 

are lighter, less complex and easier to produce. In various 

projects, ZAL and its partners are testing SPE for use in 

aircraft. The InDiCa team has also already used it successfully 

in customer-specific hardware developments. 

Another technology is the so-called Time-Sensitive Networking 

(TSN). TSN is a collection of industry standards 

that extends conventional ethernet with various methods 

and protocols. The aim here is to guarantee low delays 

and high reliability, even when the network load is high, 

e.g. due to in-flight entertainment. For the cabin, TSN enables 

a shared network. One example is the Passenger 

Announcement System, which must maintain a certain 

maximum delay to ensure lip and speaker synchronization 

for speech intelligibility. Prioritization of the associated 

traffic makes this possible. ZAL GmbH tests and evaluates 

TSN in many projects and advises partners on the substandards 

relevant for their use case and a suitable network 

configuration. 

To run the ZAL Endpoint, the experts use the Zephyr 

Open-Source Real-Time Operating System designed 

for embedded systems. They operate the system, which 

the Linux Foundation supports, as a universal platform 

across projects. The team can thus reuse source codes in a 

46 — 47 

ZAL ENDPOINT IN THE MAKING 

Frank Khelfa, Hardware Development expert 

ZAL GmbH, manufacturing a new circuit board

THE PICK-AND-PLACE MACHINE 

allows precise positioning of 

components 


hardware-independent manner and benefit from crossproject 

development efforts. Based on Zephyr OS, ZAL engineers 

advance both application-specific devices and 

hardware-related drivers for customers. 

The ZAL Endpoint is a versatile hardware for use cases inside 

the cabin. The board with a standard connector is a 

platform for research and development, which combines 

the mentioned technologies for the first time in a prototype. 

It already has single-pair ethernet, an up-to-date microcontroller 

and a power supply based on 28VDC as it is 

present in the cabin. On the software side, the Endpoint 

can be used with Zephyr OS and integrates into a TSN-enabled 

network. Expansion boards can be used via a mikro- 

BUS TM header and extra connectors, depending on the application. 

The Endpoint can thus operate as a single 

element, but can also be expanded as needed. It significantly 

shortens development times for future cabin applications. 

More ZAL Endpoints in the making 

As a next step, the ZAL team will expand the ZAL Endpoint 

family by developing additional versions. These will 

include a high-performance Endpoint that features an AI 

co-processor and is suitable for use cases with higher 

performance requirements like video streaming, high 

resolution cameras or AI applications.



ZALguard 

A Small Box for Safety 

— The year 2021 was characterized by changing Corona regulations, which regularly put the 

organization of working at the ZAL TechCenter to the test. The introduction of 2G for company 

cafeterias, for example, required the control of proof of vaccination and personality checks 

at the same time. »Easy!« was the response from the technology experts at ZAL GmbH. 

And within three days, they presented a small white box ... 

48 — 49 

Can't this be built as a small ready-made box? 

A device that automatically checks the access with the QR 

code of the vaccination certificate and a ZAL ID card or 

photo ID – that was the idea of the Automation team. A 

public admission point where ZAL partners can access the 

ZAL restaurant with vaccination certificate code and ID. Although 

the team's work is especially difficult because of 

the coronavirus, the experts managed to get the ZALguard 

checking station up and running within three days. 

With ZALguard, ZAL GmbH threw its broad interdisciplinary 

know-how into one pot. From many ideas and approaches, 

experts from the fields of Automation, Additive 

Manufacturing and Data & Power Networks built the ZALguard 

box: the housing is 3D printed, hardware construction, 

camera setups, and programming are a team effort of 

Automation experts and programmers. 

How does the ZALguard work? 

The ZALguard consists of a 3D printed box. At the top is a 

display and at the bottom is a cutout for the QR code and 

the ZAL badge (or ID card). Below the badge window are a 

camera and a small mirror for optics. The camera can process 

anything that people put on it. Scanning the QR code 

works similarly to the CovPass app. The certificate data 

from the QR code is sent to the RKI, whose database then 

answers the status question, i.e. determines whether the 

vaccination certificate is valid and sends the name for 

matching. This is then compared with the ID card. In this 

way, ZAL does not have to process the data itself, also for 

reasons of data protection. ZALguard, therefore, does not 

check the data electronically but based on image. The data 

is not stored; instead only the ID card is checked. If the certificate 

is valid and the name matches, a green lamp lights 

up to indicate this. 

What else needs to be solved? 

However, this requires powerful hardware that does 

not consume a lot of power, works in a small space, 

and does not run over the large server cluster in the 

server room. The ZALguard should work on its own. 

This is because to process the images (ID cards), a high 

level of graphics processing power is required. To this


The self-made demonstrator allows automatic 

access control according to 2G rules 


end, the team is currently experimenting with NVIDIA 

hardware and training neural networks to optimize the 

hardware. This is necessary to reduce the reading time 

of the ID cards (currently still 5 seconds) because an 

ordinary PC does not provide the required performance. 

Therefore, the experts have to combine hardware 

and coding in a more optimized way. ZALguard is 

still in an experimental phase when it comes to addressing 

challenges such as poor cell phone displays, 

QR codes on wrinkled paper or faded ID cards. ZALguard 

also can't yet verify paper vaccination cards. But 

it is constantly evolving. 

What's next? 

There is no comparable inspection station like the ZALguard 

on the market yet. After the experimental phase with 

the ZALbadge, the team now wants to enable matching 

with photo ID and QR code. The next step will be a ZALguard 

for ZAL reception to relieve the staff of 3G checks.


ROBOT-GUIDED 3D PRINTING 

Robot-Guided 3D Printing 

From Pitch to International Project 

READY FOR PRINTING 

Martin Gromniak, ZAL Automation expert, 

preparing the robots for 3D printing 

50 — 51

— What will the cabin components of the future look like? LiBio – Lightweight Bionic Aircraft 

Interior – is a research project on Robot-guided Additive Manufacturing (RAM), funded by the 

German Federal Ministry for Economic Affairs and Energy. An international consortium from 

Germany, Austria and Canada is conducting joint research on the production of an aircraft cabin 

element. The aim is to jointly develop a forward-looking, sustainable and functional design. 


The consortium is working on a business class table. It 

is completely 3D printed and can be pulled out of the 

sidewall and folded out. Instead of a classic business 

class interior, e.g. with heavy leather seats, the international 

team is implementing a lightweight, bionic design, 

i.e. inspired by nature. At the same time, the experts are 

combining technical functions in the table to make it 

smarter: with a display, integrated conductor paths, 

and imprinted speakers. ZAL GmbH is paying particular 

attention to the challenges of 3D printing, such as the 

size of the table and the integration of the various functions 

that the table is to offer. 

How did the project arise? 

In 2018 ZAL GmbH pitched the idea of the company iDS 

(also from TechCenter) at the RDV Forum in Montreal. 

The focus was on new designs for the aircraft cabin. It 

was decided to use the table as a central cabin element, 

which is used a lot and characterizes the cabin layout. 

With the other partners, the project became more and 

more technical, with many new functions added to the 

table. The LiBio consortium works closely together and is 

in constant exchange: all partners do their share to make 

the project a success and have their own specializations.


ROBOT-GUIDED 3D PRINTING 

52 — 53 

What is the focus of ZAL GmbH? 

The team at ZAL GmbH is working on RAM. To be able to 

implement several functions simultaneously as quickly as 

possible, it prints using two robots at the same time. The 

special feature is that particularly large structures such as 

the business class table can be printed with both robots. 

With a footprint of 1 m x 1 m the table is very large for a 3D 

printing process. This is especially true when printing with 

technically demanding plastics, such as those commonly 

used in aviation. Until now, only a few printers can reproduce 

this. The fact that both robots print together on the 

same component is new and unique – especially with two 

different robot brands. 

Three main topics are in the foreground. The first is 

the loudspeaker. With questions like: how can you print a 

loudspeaker? What do you have to consider to make the 

sound good? And how do you conceal it inside the table? 

The second topic is the manufacturing aspect: how do you 

get two robots of different brands to work together? And 

they do so while simultaneously working on a component 

and performing different tasks. At LiBio, since both robots 

are printing, because of their size, they have to coordinate 

which one is working, when and where. 3D printing also 

presents challenges: at ZAL, the Additive Manufacturing 

(AM) team is currently establishing granule printing, which 

opens up new possibilities in terms of materials, build rates 

and part sizes. In contrast to the frequently used plastic 

wires, the team is therefore printing plastic beads. In the 

project, the engineers print technical plastics in an open 

laboratory and not commonly in closed, specified construction 

spaces. 

What are the advantages of LiBio? 

The benefits of LiBio and the associated insights are numerous: 

the cabin equipment becomes more space-saving 

and generally more functional. The components can 

be designed freely and individually. Materials and thus 

costs are saved during production, and the components 

become more functional at the same time. And – from the 

idea and a computer model to the real component – it 

takes only a few days. This short process chain even applies 

to large components. 

Outlook: what's next? 

RAM enables an automated manufacturing cell to print 

large individual components. Having robots guide different 

tools and perform many different tasks expands 3D 

printing. Furthermore, the AM team is exploring robotic 

milling and imprinting on milled or existing components. 

Robots enable almost anything in terms of geometry and 

motion. They can increase speeds or combine different 

processes. So with RAM, you can do a lot at the same time 

and do it relatively quickly. 

Of course, sustainability is also a big issue. The AM team's 

next step is to address the issues that sustainable plastics 

raise in the aerospace context. 

Consortium 

ZAL GmbH, Fraunhofer IFAM, Bombardier, F/List, Antemo 

GmbH, CRIAQ, FusiA Groupe, Inocon Technologie GmbH, 

Joanneum Research – Forschungsgesellschaft mbH. MATE- 

RIALS – Institute of Surface Technologies and Photonics, 

Laser and Plasma Processing, Queens Universtity – Structural 

and Multidisciplinary System Design Group, Rembrandtin 

Lack GmbH Nfg. KG, SinusPro GmbH, Solyxis Ingeniosite 

Manucafturiere Inc, Aerospace & Advanced 

Composites GmbH

TECHLAB OF ZAL GMBH 

System for Robot-guided Additive 

Manufacturing with collaborating robots 

INNOVATION, R& T

54 — 55 

ZAL TechCenter

ZAL TECHCENTER

56 — 57 

FIRST AND SECOND CHAIRMEN OF THE EXECUTIVE BOARD 

meet regularly for consultation. F.L.T.R.: 

Jörg Manthey, in his function as delegate of Hecas e.V.; 

Thorsten Reimetz, in his function as exemplary supplier at Silver Atena GmbH


ZAL ASSOCIATION 

ZAL Association 

Strategic Partnerships 

for Aviation 

— The ZAL Association offers in particular medium-sized companies and partners a 

participation in topics and decision-making concerning ZAL. The Association has existed 

as long as ZAL GmbH itself has. Its foundation was linked to the foundation of ZAL GmbH 

and is firmly anchored in its shareholder structure. While the three major shareholders 

Airbus, Lufthansa Technik and the City of Hamburg each have a share of 20 percent, the 

ZAL Association is nearly just as strong with a share of 18 percent, followed by DLR with 

ten percent and four Hamburg universities at three percent each. The strategic founding 

members of the Association include Hamburg Airport, the Hamburg Chamber of Commerce 

and the two Hamburg aviation associations Hanse Aerospace and Hecas. 


The founding members were to accompany the development 

of ZAL in terms of content and strategy. Hamburg 

Airport, for example, has been an important partner 

from the outset in promoting the topic of hydrogen. 

And in addition, ZAL GmbH was managed from office 

space at the airport terminal until the completion of 

ZAL TechCenter. There has also been a close exchange 

with the Hamburg Chamber of Commerce since the 

company was founded, whether in the Chamber's Innovation 

Committee or in specialist networks, for example 

on the subject of 3D printing. In addition, ZAL GmbH 

has created three apprenticeship positions since its inception. 

The latter two founding members are of particular 

importance because Hanse Aerospace as well as


ZAL ASSOCIATION 

Hecas represent the voice of the medium-sized aerospace 

industry and have thus secured the interests of 

many relevant stakeholders from the very beginning of 

ZAL. Hanse Aerospace, for example, as the largest independent 

association of suppliers and service providers 

daily work. The members of the ZAL Association are also 

an integral part of all networking activities and professional 

events, which gives them direct access to Airbus, 

Lufthansa Technik, DLR as well as other research partners 

and facilitates the initiation of cooperations. 

The concrete implementation of the Association's organizational 

possibilities is tied to the two positions of 

the first and second chairmen of the executive board. 

Jörg Manthey, first chairman in his function as delegate 

of Hecas e.V., represents the voice of the Association in 

the quarterly meetings of the ZAL Supervisory Board. 

Thorsten Reimetz, second chairman in his function as an 

exemplary supplier at Silver Atena GmbH, represents 

the Association at the ZAL shareholders' meeting, which 

58 — 59 

JÖRG MANTHEY 

Teccon GmbH & Hecas e.V. 

to the aerospace industry, represents small and medium-sized 

companies, while Hecas is an association that 

represents the interests of northern German engineering 

service providers and consulting companies. In the 

meantime, more than 20 members have joined the ZAL 

Association – additional small companies, suppliers and 

research partners. 

Participation in the ZAL Association offers its members 

a variety of benefits: in the founding period, this included 

having a say in the design of the new ZAL TechCenter 

building with its hangars, laboratories, offices and research 

infrastructure. Currently, it is the right to play a 

part in the realization of the ZAL extensions. In addition, 

members have privileged access to research infrastructures 

and rental of premises for their own use in their 

THORSTEN REIMETZ 

Silver Atena GmbH 

takes place once a year. The third person, Nils Stoll, represents 

the interests of the board in his function as a 

board member of Hanse Aerospace. The chairmen are 

currently giving topics related to digitalization and hydrogen 

applications top priority.


ZAL ASSOCIATION MEMBERS 

ZAL TECHCENTER


SIGNAGE FOR ORIENTATION 

Black Lines 

An Aeronautical Signage 

for Orientation 

— Signage is used for spatial orientation of people in a complex building. 

In 2021 one of them was implemented in the ZAL TechCenter. The Hamburgbased 

Studio Gourdin devised and implemented the signage. 

60 — 61


The special feature of an identity-promoting signage is 

its difference to a conventional wayfinding system. 

The conception and design of a signage is more than 

just an arrow on a sign. Rather, it combines the requirements 

of orientation, wayfinding and safety for 

users with the history of the place, thus giving it an 

identification. Good signage informs and enhances the 

quality and value of the place in which it is implemented. 

It emphasizes its traits and characteristics, it explains 

the place and space by means of narration. 

Thus, the service of pleasant, good way finding is directly 

related to the image and claim of the place. The interaction 

results in an optimal overall system that also becomes 

an emotional experience. 

In the implementation of a signage for ZAL, Studio 

Gourdin decided on an approach that on the one hand 

is closely related to the theme of aviation and on the 

other hand takes into account the existing architectural 

features of the building. The design, which at first glance

62 — 63


SIGNAGE FOR ORIENTATION 

appears very simple, is based on black lines that dynamically 

relate to each other. Only at second glance do the 

lines turn out to be the marking lines of airport aprons. 

From a bird's eye view, the lines, which are actually yellow, 

indicate runways and provide orientation to taxiways, 

parking lots for aircraft and airport infrastructure. 

The large-scale wall designs in the TechCenter 

represent sections of real existing aprons. In addition, 

the design concept picks up on the research center's 

parking system, which is modeled on a runway. 

The design of the orientation arrows in front of the elevators, 

in corridors, and in front of meeting rooms is 

also taken from reality. However, the system is not 

based on airports here, but on the architectural design 

of the hangar windows. The round angles of the glass 

fronts of the ZAL TechCenter are one of the building's 

distinctive identifying marks. The angles used for the 

arrows of the wayfinding system are identical to this. 

All in all, the signage blends into the building structure 

without contradiction in its abstractness. It provides 

functional signposting, while as a pleasant side effect 

strengthening the identity and significance of the ZAL 

TechCenter as a place geared toward aviation. 


APRONS 

The design of the walls in the canteen 

is based on existing airport aprons

64 — 65

ZAL Events 

EVENTS

ZAL EVENTS 

ZALvirtual 

ZALvirtual 

Get Together Online 

— At ZAL, networking is a priority to connect people from aviation for new projects, 

ideas or simply to exchange thoughts with each other. Due to the current situation, on-site 

events are still the exception. And online events offer interesting content, but no exchange 

among participants... or do they? The Event team has come up with an online tool bringing 

participants together again and allowing exchange like in real life – ZALvirtual. 

66 — 67 

ZALvirtual is an innovative digital interaction platform 

that focuses on networking and knowledge exchange. 

Participants can interact with each other in a variety of 

ways. They move around in the digital twin of the event 

area of the ZAL TechCenter, in true-to-life 3D replicas of 

the auditorium, innovation marketplace and foyer. They 

explore the virtual environment as avatars – in real time 

and almost as if they were live on site. They are free to 

choose which other guests they interact with. Discussion 

groups of up to 15 people can thus talk to each other via 

the video and audio functions or one-on-one via chat. 

In contrast to the classic video conferencing programs, 

such as Zoom, MS Teams, etc., groups and people find 

each other faster and more intuitively. The Event team 

can thus organize meetings and conferences even 

with large groups. Furthermore, the location can be 

equipped with various furnishings and, in some cases, 

interactive elements – e.g. rollups, booths with exhibits 

as well as links to websites, screens with videos, etc. 

– depending on the requirements and event format. 

The ZAL Event team launched the new platform with 

the info event about the ZAL expansion ›Bigger, Better, 

Visionary‹ in September. Later in December, a mulled 

wine afternoon showed that the new tool was suitable 

for having snacks and drinks together. Participants 

were sent packages to their homes beforehand. And 

so, almost like in the olden days, they were able to 

enjoy some festive cheer with friendly colleagues and 

mulled wine at hand. The ZAL Science Slam proved 

that hybrid also works exceptionally well. In the real 

ZAL auditorium, 90 people were seated, while 75 

participants watched the slams online and voted on 

them, too. There was also a get-together in the virtual 

Innovation Marketplace afterwards. 

ZALvirtual opens up completely new possibilities for 

online events, but also hybrid events. Through online 

events, a more international audience can now easily 

participate in events at ZAL TechCenter.

THE DIGITAL TWIN 

of the ZAL event areas is used by participants with an 

avatar. ZALvirtual enables the attendance of on-site and 

digital participants at the same event at the same time 

EVENTS 

NETWORKING ONLINE 

At the virtual Innovation Marketplace participants 

can exchange ideas, visit digital booths and more


ZAL INNOVATION TALKS 

ZAL Innovation Talks 

5 Years from now 

— The ZAL Innovation Talk series continued in 2021 with top-class speakers and hot topics. 

A national and international audience thus gathered online to absorb the latest trends and 

developments in aviation and to ask their questions to the experts. 

68 — 69 

the plans for Airbus' ZEROe fleet, the event focused 

on questions like: how does aviation need to evolve in 

terms of sustainability? What role does open innovation 

play in this? And why is diversity so important for the 

future of aviation? 

AEROSPACE PROPULSION TECHNOLOGIES 5 YEARS FROM NOW 

F.L.T.R.: Dr. Susan Ying, SVP of Global Operations at Ampaire, 

Bjorn Fehrm, Lead Technical Analyst at Leeham Co. and ZAL's CEO Roland 

Gerhards discussed with moderator Lukas Kaestner 

some key questions related to the future of aviation 

At ›Aerospace Start-ups 5 Years From Now‹, moderated 

by Lukas Kaestner from Hamburg Aviation, Roland Gerhards 

spoke with renowned serial founder and investor 

as well as co-founder of Sustainable Aero Lab Stephan 

Uhrenbacher about start-ups in aviation and what they 

will contribute to zero-emission flying. 

Kaestner and Gerhards also talked about the big topic 

of sustainability in aviation with Grazia Vittadini, at 

this point still CTO of Airbus, in the ZAL Innovation 

Talk ›Green Aviation 5 Years From Now‹. In addition to 

›Passenger Experience 5 Years From Now‹ addressed 

inflight experience and related trends. Gerhards and 

Kaestner spoke with John Walton, one of the world's 

most renowned trade journalists in the field of aircraft 

interiors and in-flight products. 

Flying cabs and ambulance drones – hardly any other 

aviation segment is as hyped as Urban Air Mobility. 

That's what Flavia Ciaccia, the vice president of user 

experience at EmbraerX spinoff Eve Air Mobility, talked 

about at the ZAL Innovation Talk ›Urban Air Mobility 5 

Years From Now‹. 

›Aerospace Propulsion 5 Years from Now‹: from different 

perspectives, Dr. Susan Ying, SVP of Global Operations 

at Ampaire, and Bjorn Fehrm, Technical Analyst at 

Leeham Co., discussed hydrogen propulsion, all-electric 

or hybrid-electric flying and the next generation of propulsion 

technologies.


ZAL EXPANSION 

ZAL EXPANSION 

The expansion of ZAL promises to make the research center bigger, better 

and even more visionary. New Work principles will be the focus here 

Bigger, Better, Visionary 

The ZAL Expansion 

EVENTS 

— At the online event ›Bigger, Better, Visionary – a Preview of the ZAL Expansion‹ 

Roland Gerhards, CEO of ZAL, gave participants an insight into the current plans. 

After all, ZAL is set to grow. The expansion is a joint effort 

of the city of Hamburg and the ZAL shareholders, 

and will bring more space for innovation to aviation. The 

construction projects are the expansion of the current 

ZAL TechCenter, all the way to the street, as well as the 

new aviation research campus on the grounds across 

the street. There will also be a parking garage there. ZAL 

will grow to about 1,100 workstations. 

The new campus is a New Work vision that is currently 

taking shape. The building will be a cube with an inner 

courtyard adjoining the parking garage. It will be built in 

a completely climate-neutral manner and will be 

greened, yet still visually resemble ZAL as it is known. 

ZAL is working with Fraunhofer IAO to design the new 

building. In his presentation, Dennis Stolze gave an 

overview of the importance of shared workplaces for innovation 

processes – ›New Work in the Post-corona 

World‹. This concerns not only the spatial but also the 

technological, organizational and cultural components 

of the work environment. There will be a suitable workplace 

for every task. The entire ZAL ensemble thus becomes 

a campus for technology, innovation and new 

work – including coaching tailored precisely to aviation.


ZAL DIGITAL TECHWALK 

Digital TechWalk 

Experience ZAL live and on screen 

70 — 71 

VIRTUAL CABIN MOCKUP 

Mara Fuchs, Research Associate at the DLR Institute 

of System Architectures in Aeronautics, demonstrated 

how the virtual cabin works 

— At the Digital TechWalk, the ZAL TechCenter opened its doors for the second time. 

The participants explored the building via live broadcast and gained exciting insights 

into the collaborative work of the resident companies. 

After a welcome in the newly designed reception area, 

cameras switched to the first project presentation in 

Hangar A: here, Christopher Petermann (Engineer for 

Innovation and Research Projects, Lufthansa Technik) 

and Dr. Leonid Lichtenstein (Head of the Data & 

Power Networks, ZAL GmbH) introduced the joint 

research project ReSa. For this government-funded 

project, a team of experts currently develops an 

independent retrofittable sensor system architecture 

for Predictive Maintenance. 

The next stop featured DLR’s virtual cabin mockup. 

Here, the institute investigates the integration and 

connection of data in the cabin design process to 

an immersive virtual environment. Presenters Mara 

Fuchs and Florian Beckert (both Research Associates 

at the DLR Institute of System Architectures in 

Aeronautics) demonstrated how experts can move 

around the virtual cabin and interact with the various 

components. 

At the final presentation in the ZAL TechLab, Dr. Thorsten 

Scharowsky (Head of Advanced Materials, ZAL GmbH) 

showcased ZAL's additive manufacturing system of 

currently three robots, which is used to investigate how 

the printing of complex parts on uneven surfaces can 

succeed.


SCIENCE SLAM 

ZAL SCIENCE SLAM 

Good vibes at the first and only 

big on-site-event at ZAL this year 

EVENTS 

ZAL Science Slam 2021 

Chicken Wings and AI 

— What do a dwarf poodle and chicken wings have in common with AI? 

How do you chase blue lights across the information superhighway? 

Is this ›The Wind of Change‹ for aviation? Once again, we 

learned and, above all, laughed a lot at the ZAL Science 

Slam. At the evening event organized by ZAL GmbH 

and Hamburg Aviation, six slammers competed against 

each other, presenting their scientific topics with humor 

the guiding principle. The speakers came from Airbus, 

Beagle Systems, Thelsys GmbH and ZAL GmbH. 

And who won? The audience, who attended virtually and 

on-site, voted Oliver Lichtenstein, co-funder of Beagle 

Systems, as the winner of the Science Slam.


ITS WORLD CONGRESS 

ITS Wold Congress 

Technical Visit at ZAL 

— Hamburgs ITS World Congress in October 2021 offered 

attendees the opportunity to visit companies, 

institutions and research facilities to take a look behind 

the scenes. During the congress, one of these socalled 

technical visits was hosted at ZAL. Participants 

learned about ZAL’s Open Innovation approach and Innovation 

Service while gaining insights into the stateof-the-art 

infrastructure like AI Aviation Lab or Cabin & 

Cargo Testrig at a guiding tour through the TechCenter. 

After an introductory presentation about the history 

of hydrogen and fuel cells in aviation, current projects 

were presented in three expert pitches about digital 

cabin concepts, recent automation project safety AGV 

as well as new acoustic challenges and concepts. The 

experts were also on-site for exchange. 

72 — 73 

GUIDED TOUR OF THE ZAL TECHCENTER 

Uwe Seeland, Consultant Cabin & Systems, 

ZAL GmbH, gave the participants of the Technical 

Visit a guided tour through the building


HAMBURG 1 SHOOTING 

HAMBURG IS BOARDING 

Scan to watch the TV report 

Hamburg 1 Shooting 

ZAL Research Activities on TV 

EVENTS 

— In the new TV magazine ›Hamburg is boarding‹, local broadcaster HH1 presents 

aviation topics from the metropolitan region in cooperation with Hamburg Aviation. 

The first issue presents activities from the ZAL TechCenter. 

The opener of the tv report is the current situation: 

how is the aviation industry responding to the developments 

of climate change and Covid19? And what are the 

current activities in this regard at the ZAL TechCenter? 

The DLR institutes based at ZAL, ZAL GmbH itself and 

the Sustainable Aero Lab present their roadmap to 

more sustainability in aviation in the TV report. In all 

three contributions, it becomes clear that hydrogen 

as an energy carrier is a central component of the future 

of aviation. The focus at ZAL is on the integration 

of fuel cell systems. To this end, digital simulations and 

research activities on test stands are being carried out 

by the players. 

Relevant to future developments in aviation is the Sustainable 

Aero Lab, established in 2021. While the startup 

presented in the tv report also focuses on hydrogen, 

the Sustainable Aero Lab's focus is on sustainable aviation 

start-ups in general. Thus, important impulses for 

the future can still be expected from this area.


IMPRINT 

ZAL CENTER OF APPLIED 

AERONAUTICAL RESEARCH 

Hein-Sass-Weg 22 

21129 Hamburg 

Germany 

T +49-40-248-595-0 

E info@zal.aero 

W www.zal.aero 

twitter.com/zaltechcenter 

linkedin.com/company/zaltechcenter 

facebook.com/zaltechcenter 

xing.com/pages/zalzentrumfurangewandteluftfahrtforschunggmbh 

zal.aero/newsletter 

PHOTO CREDITS 

Daniel Reinhardt 

Axel Heimken 

EDITORIAL 

Lisa Becker, ZAL GmbH 

Miriam-Joana Flügger, ZAL GmbH 

Lukas Kaestner, Hamburg Aviation e.V. 

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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