FUTURED. ZAL Magazin 2025
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Future. Created in Hamburg.
r2025
WHAT’S IN FOR ME?
H 2 FORECAST
Check out the aviation horoscope
for 2025 and stay tuned
for the next ZAL.award.
Maritime joins H 2 research at ZAL.
And Hamburg updates Green
Aviation Roadmap.
ZAL MAGAZINE
T
2025
u
U
e
FOR WORK OR LEISURE?
This FUTURED magazine
provides tech news, podcasts,
a crossword puzzle and
info on the ZAL kicker league.
['fju t∫әd]
FUTURED is an adjective … describing what
we do. We shape the future of aviation.
Every day. Together. The FUTURED magazine
is a part of this, showing what we strive
for, what we implement, and how we do it.
We are progressive, passionate, and visionary.
We are futured.
Future. Created in Hamburg.
FUTURED.
ZAL MAGAZINE
2
“Joint H 2 research
fosters innovation in
aviation and maritime.”
Prof. Dr.-Ing. Carlos Jahn
Roland Gerhards, CEO ZAL, (right) welcomes
new ZAL tenant: Prof. Carlos Jahn, Head
of Fraunhofer Center for Maritime Logistics
and Services.
HYDROGEN RESEARCH
AT ZAL: MARITIME
GETS ON BOARD
In the context of the H 2 AM (Hanseatic Hydrogen Center
for Aviation and Maritime) funding initiative, the city of
Hamburg has tasked its two leading sectors, aviation and
maritime, with developing and testing hydrogen- and
fuel cell-based technologies under real-world conditions.
The goal is to make a significant contribution to decarbonization.
A great challenge – one that, the city hopes,
can be met through the synergies of joint research.
GERHARDS Hello, Professor Jahn, and welcome to ZAL Tech-
Center! We are delighted that Fraunhofer CML has chosen our
facility as the home for its Fuel Cell Integration Center laboratory
– also known as FCIC – dedicated to the research and development
of fuel cell systems for maritime applications.
JAHN Thank you, our scientists are also looking forward to
bright and spacious facilities as well as the opportunity to operate
our fuel cell in your well-equipped environment and
start our work at our new location.
GERHARDS Would you please introduce Fraunhofer CML to
our aviation partners. What are your focus areas?
JAHN ”Innovating the Maritime Sector” is the guiding principle
at Fraunhofer Center for Maritime Logistics and Services, CML
in short. True to this mission, the Hamburg research institution
contributes to improving sustainability and process efficiency
in maritime operations, port handling and service concepts
through AI applications. New solutions for autonomous systems
as well as the digitalization of navigation and communication
further enhance the safety and ease of maritime traffic.
GERHARDS CML has a modern new research facility in Hamburg-Harburg.
How do you justify the move to ZAL to your
own industry peers and beyond?
drogen, a new research field for Fraunhofer CML. You have
appropriately equipped laboratories at ZAL TechCenter, allowing
us to benefit from the existing infrastructure, which
gives us a time advantage in achieving our research goals.
But besides the existing hardware, there are also substantive
reasons to seek proximity to aviation. We face similar
challenges.
GERHARDS That’s true, infrastructure, refueling, high demands
for reliability and safety along with climate conditions are topics
that affect both of our industries and bring us together.
What topics will you be giving priority to in the new lab?
JAHN In the new Fuel Cell Integration Center, our researchers
will investigate the use of fuel cell technology in the maritime
sector and co-develop the necessary solutions. As in aviation,
special requirements are a priority on board a ship, albeit different
ones. Ship movements, temperature fluctuations, high
UV radiation, humidity and corrosive conditions place high
demands on the materials used.
GERHARDS Yes, environmental effects on materials and systems
are challenges for us as well. How do fuel cells perform
under different air pressures, and how do various materials
behave at -253 degrees Celsius, the temperature of liquid hydrogen?
To explore these questions, we will be implementing
an altitude chamber and a cryo chamber at ZAL.
JAHN Exciting. We look forward to exchanging ideas on these
and other topics. The ZAL network represents a significant
added value for us in this context: innovative companies that
take on new challenges as well as researchers solving
comparable tasks present an opportunity for us to expand
the boundaries of knowledge with new clients and research
partners.
3
JAHN We are taking up the lab spaces as part of H 2 AM: to advance
decarbonization, the maritime sector must turn to hy-
GERHARDS I completely agree – our strength lies in collaborative
research.
CONTENTS.
AI &
DIGITALIZATION
AUTOMATION &
MANUFACTURING
HYDROGEN &
SUSTAINABILITY CABIN MRO
IMPULSES &
OUTLOOK
4
The FUTURED magazine is for reading,
listening and watching!
Article
Audio
Video
Website
06 IMPULSES & OUTLOOK Crossword Puzzle
08 IMPULSES & OUTLOOK When Aviation Meets Maritime: Joint H 2 Research at ZAL
10 LUFTHANSA TECHNIK A Home for Sustainable Innovation
12 SFS Sustainable Material Management
14 ZAL GMBH Greencode vs. Power-Hungry Software
16 IDS INDUSTRIAL DESIGN STUDIO Cabin Design Study with VÆRIDION
18 IMPULSES & OUTLOOK ZAL.award: When Teamwork meets Innovation
20 IMPULSES & OUTLOOK ZAL.award Winner 2024: Hydrogen Aviation Lab
22 DIEHL AVIATION “Have the Courage for New Ideas!”
24 ESPLORO PROJECTS National Interests and European Collaboration
26 AKKODIS Transforming Aviation for a Sustainable Future
28 DLR, MAINTENANCE, REPAIR & OVERHAUL The Go-To Place for MRO Research
30 DLR, MAINTENANCE, REPAIR & OVERHAUL Every Lab Counts
32 IMPULSES & OUTLOOK Hamburg Updates Green Aviation Roadmap
34 DLR, ENGINEERING THERMODYNAMICS DLR’s Multi-Stack Test Rig for Hydrogen Aviation
36 DLR, SYSTEM ARCHITECTURES IN AERONAUTICS Opening the Room for a New Era in Aviation
38 DLR, SYSTEM ARCHITECTURES IN AERONAUTICS Think Ahead, Supply Chain in Mind
40 JETLITE A Science-Driven Vision
42 FFT Aircraft Production – Intelligent Automation at Every Phase
44 IMPULSES & OUTLOOK 2025 in Charts: Aviation’s Make-or-Break Year for Innovation
48 ZAL GMBH Built to Last, Easy to Recycle
50 AIRBUS The World’s First Thermoplastic Fuselage at ZAL
52 FRAUNHOFER IFAM Major Component Assembly of MFFD
54 FRAUNHOFER IFAM Optimized Aircraft Fuselage Assembly
56 CAPGEMINI Digital Twins: Bridging Physical and Virtual Worlds with XR
58 IMPULSES & OUTLOOK Kicks & Collaboration
62 TECCON Hydrogen Takes Off – Sustainably into the Future
64 PRODOSE Visioportation – Teleportation Is Now!
66 SIEMENS Virtual Certification Using the Digital Thread
68 IMPULSES & OUTLOOK ZAL Expert Community
70 FEV FEV Detects High-Voltage Discharge in Aerospace
72 ZAL GMBH H 2 -Drones: From Prototype to Commercial Reality
74 THELSYS What Weight Is Your Innovation?
76 IMPULSES & OUTLOOK Hamburg Aviation Green Podcast
78 IMPULSES & OUTLOOK The Potential of proTechnicale Alumnae
80 Imprint
5
IMPULSES & OUTLOOK
BECOME
LEGEND …
1
The first episode
of a (Netflix) series.
4
5
… on our (not yet famous) wall of
fame! Crack the URL of this ultra -
challenging crossword puzzle – and
remember: the toughest challenges
are best tackled as a team.
Have fun!
3
Typical color
of Kuka robots.
1
6
3
Greek wind god
and Linux operating
system.
7
NAME OF ZAL
RESEARCH
CENTER.
8
11
6
WHAT WORD DOES
THE D IN THE ACRONYM
LIDAR STAND FOR?
2
4
Airplanes
and ZAL
have two.
WHAT DOES
PEM STAND
FOR?
FAVORITE DISH ON
MONDAYS.
THE HEART OF
AIRCRAFT
MANUFACTURING.
CROSSWORD PUZZLE
2
MAIN BODY
OF AN
AIRPLANE.
Answers consisting of
multiple words are written
as one word, no spaces, no
special characters, figures
are written out in full.
SURNAME OF THE
WINNER OF THE ZAL
SCIENCE SLAM 2024.
9 10
USED FOR
TAKEOFFS AND
LANDINGS.
5
1. Write out: the number
of the ferry between
Rüsch Park and
Teufelsbrück.
2. Airbus project for
hydrogen-powered
aircraft.
3. Extendable, high-lift
devices on the leading
edge of an aircraft
wing to increase lift at
low speeds.
4. Study of forces acting
on objects in flight.
Canteen operator at ZAL.
12
13
German aviation
pioneer.
6
REFERRED
TO AS
JET-A OR
JET-A1.
5. Name of the ferry
pier opposite Teufelsbrück.
6. What is ZAL Tech-
Center‘s house
number?
7. An initial model or test
version of a design
used for evaluation
and research.
8. Streaks of cloud-like
vapor formed by aircraft
engines at high
altitudes.
7
14
Backup device
providing power
to essential AC
systems during an
emergency.
15
7
8
GERMAN
HOME-
TOWN OF
THE BOEING
FAMILY.
9
9. AC manufacturer
aiming to compete
with Boeing and
Airbus.
10. Acronym for Robotguided
Additive
Manufacturing.
11. Term for really cold
liquid like LH 2 .
12. Kitchen area on an
aircraft.
13. High speeds in the air
and at the kicker table.
14. The height of an aircraft
above sea level.
15. Location of Paris Air
Show in 2025.
www.zal.aero/
1 2 3 4 5 6 7 8 9
IMPULSES & OUTLOOK
WHEN AVIATION
MEETS MARITIME:
JOINT HYDROGEN
RESEARCH AT ZAL
8
In March, ZAL received a funding of 12 million
euros to expand its hydrogen research
and, for the first time, initiate a collaboration
with the maritime industry to jointly
advance hydrogen applications. The funding
provider is the German Federal Ministry
for Digital and Transport (BMDV).
With a total funding of 69.8 million euros,
BMDV is supporting the establishment of a
North German Hanseatic Hydrogen Center for
Aviation and Maritime (H 2 AM), which aims to
drive hydrogen and fuel cell research in aviation
and maritime at three locations: Hamburg,
Stade and Bremen / Bremerhaven. Responsibility
for the Hamburg-based projects
lies with ZAL GmbH and the Fraunhofer Center
for Maritime Logistics and Services (CML).
ZAL is utilizing the funding to expand its inhouse
Fuel Cell Lab. This includes the provision
of a hydrogen liquefier as well as the construction
of two test chambers: one for altitude simulation
and another for cryogenic applications
with liquid hydrogen at -253°C. The facility is
designed to support stakeholders engaged in
hydrogen research and development. In alignment
with H 2 AM, the expansion will particularly
focus on filling gaps in testing and certification
services currently lacking in the market,
while also fostering international collaboration
to establish standards. To this end, ZAL
offers start-ups, SMEs as well as industry and
research partners an ideal development environment
to position themselves competitively
on a global scale.
A new milestone for ZAL is the upcoming collaboration
with the maritime industry. For this
purpose, Fraunhofer CML, also a recipient of
H 2 AM funding, will establish a laboratory within
the ZAL Fuel Cell Lab. The joint research will
focus on system integration, infrastructure, refueling
as well as the reliability and safety of
hydrogen applications. To achieve these goals,
ZAL will interconnect existing experts, bring in
new external partners and build fresh collaborations.
Hamburg’s already strong hydrogen
network will gain further momentum. ZAL and
CML expect significant synergy effects from
this partnership, bringing aviation and maritime
closer to their shared objective of reducing
emissions in mobility.
WHEN AVIATION MEETS MARITIME: JOINT HYDROGEN RESEARCH AT ZAL
H 2
9
“The expansion of our existing hydrogen infrastructure
and the new collaboration between
aviation and maritime are crucial steps toward
emission-free mobility. With the addition of a
liquefier and two test chambers, we are strengthening
our research foundation and creating
new opportunities for both current and future
hydrogen stakeholders.”
Roland Gerhards, CEO ZAL
LUFTHANSA TECHNIK
Inside a 20-meter segment of a
retired A320, Lufthansa Technik
is researching resource-efficient
cabin interiors.
10
A HOME FOR
SUSTAINABLE
INNOVATION
CONTACT
Christoph Lieske
christoph.lieske@lht.dlh.de
Since 2023, Lufthansa Technik has been operating
its Airbus A320 cabin mock-up at
the ZAL Center of Applied Aeronautical Research
in Hamburg. What started as a retired
aircraft from the Lufthansa Group has
now become a dynamic research hub.
The journey to its new home was no small
feat – cutting a 20-meter section from an A320,
transporting it from Lufthansa Technik’s base
at Hamburg Airport through the city toward
Finkenwerder, installing it at ZAL TechCenter,
and later relocating it to the recently extended
research space, where it has now reached its final
destination. Now fully operational, the mockup
offers a real aircraft environment for testing
and validating new technologies, making it an invaluable
asset for innovation.
The cabin has been carefully refurbished, featuring
a complete galley, two lavatories, eleven
rows of economy seating, and standard cabin
lining. Additionally, it includes a six-meter open
space for flexible installations, along with a reactivated
air conditioning recirculation system.
These enhancements make it a versatile testing
platform for a wide range of research and development
topics in aviation.
Already, the mock-up has been instrumental in
projects such as wireless data communication
within the cabin and the testing of innovative
A HOME FOR SUSTAINABLE INNOVATION
graphene-based materials for air filtration. But
its potential doesn’t stop there: ongoing research
continues to push the limits of innovation, especially
in aircraft cabins and sustainability.
THE RECAB PROJECT:
PIONEERING A RESOURCE-EFFICIENT
FUTURE FOR AIRCRAFT CABINS
One of the latest projects leveraging the A320
mock-up is RECab, a research program aimed
at making aircraft cabins more resource-efficient.
RECab, funded by the Federal Ministry
for Economic Affairs and Climate Action, brings
together Lufthansa Technik, Diehl Aviation and
Hamburg’s top universities (TUHH and HAW
Hamburg) to explore resource-efficient solutions
for future aircraft cabins.
Sustainability in aviation is a complex challenge
– it requires balancing ecological, economic
and social factors. RECab takes a holistic
approach, ensuring that new materials and technologies
are not just environmentally friendly
but also economically viable and socially compatible.
One of the project’s key innovations is
the development of an ESG score, based on
28 key performance indicators, which assesses
sustainability across all 17 United Nations Sustainable
Development Goals. Another crucial
aspect is integrating sustainability into product
development processes, identifying key decision
points that impact long-term environmental performance.
• GuideU
Lufthansa Technik’s non-electric floor path
marking system is undergoing a sustainability
transformation. The project is exploring recycling
strategies to recover valuable raw materials
and designing a fully circular version of
the product. New luminescent elements and
scratch-resistant surfaces serve to extend
product lifespan and facilitate unlimited reuse.
• Optimizing the potable water
system refueling
Reducing an aircraft’s weight directly lowers fuel
consumption and CO 2 emissions. Many older
aircraft models lack precise system control
over potable water use, often leading to excess
onboard water weight. RECab is developing
smart monitoring and automation solutions,
such as automatic water consumption tracking
and demand-driven refueling. To test these
advancements, two demonstrators have been
built: one featuring an original A320 potable
water system and another incorporating A330
tank components. Additionally, the potable water
system of the A320 mock-up has been fully
reactivated for system integration tests and
performance validation.
11
Technologically, Lufthansa Technik is driving multiple
initiatives within RECab, including the evaluation
of AeroFlax, improvements to GuideU,
and enhancements to potable water system efficiency.
• AeroFlax
This natural flax-fiber composite material is
being tested for its heat resistance and suitability
in aircraft interiors. With weight being a
critical factor in aviation, comparing AeroFlax
with conventional fiberglass composites could
open new possibilities for lightweight, sustainable
cabin materials.
Lufthansa Technik’s research platform has relocated to its new home in
the expanded ZAL facility.
SFS
SUSTAINABLE
MATERIAL
MANAGEMENT
12
Learn more
about SFS here.
Back in the day, materials were chosen in
the aviation industry based on maximum
safety and high performance with minimum
weight. The focus was on the impact
of each component on “its” environment,
not what making, operating and disposing
it meant for our environment.
The aviation industry has been undergoing a
change of view on this in the past few years, realizing
that ecological footprints have to be a
major factor in all decisions. SFS is closely examining
ways of manufacturing its products in a
way that uses fewer resources and increasing
the recyclability of the materials used.
RAFINESS is a German-Austrian project with
eight corporate partners that has set itself the
goal of achieving “environmentally friendly aviation”
with the aid of robot-guided additive manufacturing
on cabin sandwich structures. Taking
an aircraft luggage rack as an example, a concept
was developed for how to optimize future
brackets for lightweight structures and integrate
them into honeycomb structures.
The biggest challenge for SFS was to cut the
number of materials in existing fastening systems
for aircraft luggage racks and replace them
with a single recyclable and bio-based multigrade
polymer. Analysis quickly revealed that no
single material can meet all the requirements.
Modern cabin components are acoustically separated
from the fuselage structure, so as not to
transmit the noise of the engines and air flow
inside. Unfortunately, the properties of the materials
used for damping elements are very often
the opposite of those that ensure fuselage
and cabin are firmly connected.
MATERIALS THAT CAN BE
RECYCLED ARE KEY TO
MAKING EFFECTIVE USE OF
NATURAL RESOURCES.
Conventional damping elements: “shock mounts”
made of silicone rubber (VMQ) and aluminum.
SUSTAINABLE MATERIAL MANAGEMENT
13
Recyclable damping elements, retaining rings and structural mounts based on polyamide.
THE COMBINATION
OF MATERIALS IS CRUCIAL
The damping elements used in modern aircraft
usually consist of silicone rubber for the damping
properties and inner and outer rings of metal
(often aluminum) for a firm fit so the cabin elements
do not fall on passengers’ heads even in
the unlikely event the rubber fails. Sadly, it is precisely
this combination of materials that cannot
be reused. First, because silicone rubber cannot
be remelted or reshaped once it has been vulcanized.
Second, because the metal components
have to have a bonding agent applied to ensure
good adhesion. The bonding agent and the rubber
residues mean the metal components cannot
be used again as load-bearing structural
components in the aviation industry.
What was needed was a material possessing
both the damping properties of silicone rubber
and, with additional additives, the necessary
strength of metal. With the support of its project
partner Fraunhofer Institute for Environmental,
Safety and Energy Technology UMSICHT, precisely
such polyamide-based materials were found.
There is a thermoplastic elastomer (TPE) based
on polyamide for its damping properties, as well
as a newly developed fiber-reinforced polyamide
10 from the institute, which additionally consists
of up to 60% renewable raw materials and can be
used in robot-guided additive manufacturing.
Both materials can be mechanically separated
from each other and thermally reprocessed into
new products, making it possible to use sustainable
damping elements in the aviation industry.
CONTACT
Marc Dibowski
marc.dibowski@sfs.com
ZAL GMBH
GreenCode helps lower power
usage from inefficient software.
14
GREENCODE VS.
POWER-HUNGRY
SOFTWARE
CONTACT
Dr. Johannes Passand
johannes.passand@zal.aero
Software is an often-overlooked climate
factor: the rising energy consumption of inefficient
applications is increasingly seen as
a contributor to global emissions. Project
GreenCode aims to change this: a framework
designed to help developers make
their code more sustainable.
Software drives many modern devices – from
controlling a simple coffee machine to processing
complex data in industrial applications. The
requirements for software are diverse: security,
performance, scalability and reliability. However,
one aspect often falls by the wayside: energy-efficient
programming. Under pressure of tight
deadlines, energy consumption is often overlooked.
But careless programming can result in
unnecessary loops and memory operations,
overloading the device. Switching to a more efficient
programming language alone can reduce
energy consumption by up to 70 percent.
A TOOL FOR EFFICIENCY CHECKS
With ambitious sustainability goals and the
growing use of energy-hungry AI models, this
issue is now coming into sharper focus. A study
GREENCODE VS. POWER-HUNGRY SOFTWARE
by Salesforces shows that 75 percent of developers
would like to pay more attention to resource
conservation in their work.
Read more about project
GreenCode.
One solution could be the GreenCode research
project, which aims to provide developers with
tools for efficiency checks. The concept: code is
automatically tested for energy and resource
consumption, with an AI model suggesting more
efficient programming alternatives.
tool during development. This will involve automatically
measuring and comparing the electrical
energy consumption, memory usage and
CPU resources of different algorithm variations.
SAVING ENERGY WITH
EXISTING HARDWARE
GreenCode offers great potential for the aviation
industry: it could reduce weight and energy
consumption during operation of an aircraft and
better utilize the performance of existing devices,
such as lighting systems and in-flight entertainment.
Many of these devices are not constantly
in use. Using distributed computing,
these devices could take on additional tasks
during downtime, without the need for extra
hardware.
MAKING ENERGY CONSUMPTION VISIBLE
For developers, estimating how much energy
new software will consume can be difficult.
That’s where GreenCode steps in: the Intelligent
Digital Cabin team at ZAL is developing a test
pipeline to realistically evaluate the efficiency
GREENCODE TAKES FLIGHT
The project, funded by the Federal Ministry of
Education and Research (BMBF), just kicked off in
October 2024 with a strong partnership between
research and industry, led by ZAL GmbH as the
coordinator of the German consortium. Running
until the end of 2027, the international project
also includes partners from Portugal, Denmark,
Spain, the UK, Finland, Romania and Turkey. Given
the global relevance of the project’s theme, it
addresses the need for universally applicable
standards, ensuring that energy-efficient programming
practices can be adopted across different
regions and contexts. GreenCode aims to
improve the state of the art by exploring innovative
approaches, refining existing metrics for
more accurate evaluations, and promoting the
integration of green practices into standard software
development workflows and operations.
15
Source code
Architecture mining
Human-written code
Human-written code
IT landscape
GreenCode optimization
Test pipeline: energy savings, code quality
Result
GreenCode optimizes both new code and
existing software architectures, with a
test pipeline verifying the actual savings.
IDS INDUSTRIAL DESIGN STUDIO
VÆRIDION Microliner cabin
mock up – Berlin Air Show 2024.
Torsten Kanitz, CEO iDS,
Ivor van Dartel, CEO and
Co-founder VÆRIDION, and
Imme Kuhnert, iDS (l.t.r.).
16
CABIN DESIGN
STUDY WITH
VÆRIDION
Find out more about
VÆRIDION – Green
Air Mobility.
VÆRIDION GmbH, a Munich-based company
that is accelerating the green transformation
of aviation with a small electric aircraft
that will be certified and delivered
before 2030, and iDS industrial Design Studio
concluded the first cabin design study
for the VÆRIDION Microliner.
“In collaboration with the iDS team, we elevate
the travel experience to business class standards,
even on short-haul flights. The Microliner’s
cabin features an innovative design that
seamlessly integrates the highest safety standards
with unparalleled comfort, providing generous
legroom and an exceptional electric flying
experience,” says Ivor van Dartel, CEO and
Co-founder of VÆRIDION.
“The collaboration with the intelligent and
far-sighted team at VÆRIDION is extremely efficient
and fruitful. We are united by our particularly
high standards of design quality and innovation
– also in the interior,” answers Torsten
Kanitz – CEO, iDS industrial Design Studio.
CABIN DESIGN STUDY WITH VÆRIDION
Find out more about
the BIOS Future Cabin.
iDS has developed a cabin concept of the
future for FACC AG that aligns the interior
design of the cabin fully with the passenger’s
needs. The BIOS Future Cabin focuses
on the use of sustainable materials, optimal
use of the available space and the
greatest possible accessibility to digital
technologies.
FOCUS ON PASSENGER EXPERIENCE
With 20 percent more freedom of movement
and 50 percent more storage space than in current
generation aircraft, the available space has
been fully utilized. This was made possible by a
topology-optimized design approach that integrates
seamlessly into the load-bearing elements
of the aircraft.
COMPLETELY NEW HANDLING
OF MATERIALS
Ultra-light materials made from renewable raw
materials also drastically reduce the aircraft’s
CO 2
emissions.
For this purpose, a new lightweight material was
developed by FACC as part of many years of research,
which is based on sugar cane and is well
suited for use in aviation due to its properties. The
surface of this new material is not only extremely
robust, but also heat- and chemical- resistant.
COLLABORATION WITH ZAL GMBH
The ZAL GmbH engineering team provided support
in the development of ultra-lightweight
cabin components, such as the ceiling panels.
As experts for topologically optimized components
in terms of weight, among other things,
material calculations were carried out and the
design developed by ZAL GmbH and iDS industrial
Design Studio for FACC AG.
BARRIER-FREE ACCESS
A 100 percent wheelchair-accessible cabin and
a toilet that can be used without barriers also
set new standards for barrier-free flying.
CONTACT
Torsten Kanitz
t.kanitz@ids-hamburg.com
17
BIOS Future Cabin with a focus on passenger experience.
IMPULSES & OUTLOOK
ZAL.AWARD:
WHEN TEAMWORK
MEETS INNOVATION
18
At ZAL, we shape the future of aviation.
Everyday, researchers, engineers and industry
experts collaborate to turn ideas into
real -world applications. Much of this happens
behind lab doors and often stays unseen.
The ZAL.award is supposed to bring
these achievements into the spotlight and
to honor projects exemplifying collaboration,
innovation and practical impact.
WHAT'S IN IT FOR THE WINNERS?
Beyond presenting its project at the award ceremony,
the winner will receive a trophy and
the distinguished title of “Winner ZAL.award,”
both being a seal of excellence that can be
used for marketing and public relations. To
further showcase the achievement, ZAL GmbH
will produce a professional video about the
winning project, provided free of charge for
use in social media and events. Furthermore,
the winners are prominently featured on the
monitors of the ZAL TechCenter and in the ZAL
magazine FUTURED.
Interested
in taking
part?
The submission period starts on April 1 and
ends on September 30, 2025.
The winner is chosen by an independent jury comprised
of highly acclaimed individuals, brought together from
the ZAL Association network, academia, media and the
aerospace supply chain.
Find out more about the
submission procedure.
ZAL.AWARD: WHEN TEAMWORK MEETS INNOVATION
ZAL ASSOCIATION
The initiator of the ZAL.award
The ZAL.award is presented by the ZAL Association
(ZAL Förderverein), a network of 20+ innovative companies
shaping the future of aviation. The association
supports ZAL’s strategy, uniting member interests
within the shareholder structure and ensuring
they have an equal voice in decision-making alongside
major stakeholders.
More information on
ZAL Association.
Become a member of
ZAL Association.
19
ZAL e. V. board from left to right side: Sebastian Corth,
Thorsten Reimetz, Jörg Manthey and Dr. Martin Spieck.
IMPULSES & OUTLOOK
ZAL.AWARD
WINNER 2024:
HYDROGEN
AVIATION LAB
20
The A320 Hydrogen Aviation Lab is a pioneering
research project of Lufthansa Technik,
the German Aerospace Center (DLR), ZAL
Center of Applied Aeronautical Research and
Hamburg Airport. It focuses on maintenance
and ground operations of hydrogen use cases
in commercial aviation. On the occasion
of the first ZAL.award, the airport submitted
its research project and ultimately emerged
as the winner in the competition.
Congratulations on winning the first ZAL.
award, Eike. Were you surprised to win?
EIKE You can tell by the look on my face how
surprised I was. We know what a strong project
the Hydrogen Aviation Lab is, but the other entries
were also very impressive. So I was all the
more proud to be able to accept the award on
behalf of all the project partners – Lufthansa
Technik, DLR, ZAL and Hamburg Airport.
What role does HAL play in your plan to
build a hydrogen infrastructure at Hamburg
Airport?
EIKE HAL is an important key project for us. We
are working with partners on various international
projects and, thanks to HAL, we can
share our findings directly with them. This
means that the work benefits not only Hamburg
as an aviation location, but also all partners
committed to an energy transition in aviation.
And something like HAL does not exist
anywhere else in the world – it is truly unique.
What significance does HAL have on an international
level?
EIKE International partnerships are irreplaceable
for the development of a hydrogen infrastructure
at airports.
Jan Eike Blohme-Hardegen, Head of the Environment department,
Hamburg Airport, accepts the award on behalf of the Hydrogen
Aviation Lab research team.
It's actually quite simple: the aircraft that takes
off from us and lands somewhere else also has
to be refueled there in order to be able to fly
back. There are still no generally applicable
ZAL.AWARD WINNER 2024: HYDROGEN AVIATION LAB
ZAL.award
WINNER
CONTACT
Jan Eike Blohme-Hardegen
jhardegen@ham.airport.de
HAL’s winning team. Back row (from left to right): Björn Nagel, Jan-Eike Blohme-Hardegen, Gerrit Rexhausen,
Gerko Wende. Front row: Simon Beckmann, Florian Becker, Sebastian Altmann.
standards for these processes – neither regionally
nor internationally. The work in HAL is
therefore not only relevant for us, but also for
future destination airports: we are currently
helping to develop international standards for
the future of aviation and, with HAL, we are finding
the answers to many questions relating to
the handling of cryogenic liquified hydrogen in
aviation. Overall, many different projects and
research findings are necessary, which ultimately
need to interlock for the goal of implementing
a hydrogen-powered airplane to be achieved.
TULIP project, which is pursuing similar goals
to BSR, but in the Benelux region.
For the future use of liquid hydrogen in commercial
aviation, we are part of the Airbus Hydrogen
Hub at Airports project, which spans
the entire globe.
For example, we are in close contact with
Christchurch Airport in New Zealand. They are
also keeping a close eye on the experience we
are gathering at HAL.
21
Tell us more about that – what is the context
in which the work on HAL is taking
place? What international projects are you
involved in when it comes to hydrogen?
EIKE In the north, Hamburg Aiport is the lead
partner of the Baltic Sea Region HyAirport project.
Here, 16 international and 24 associated
partners are working on laying the foundation
for short-haul flights using gaseous hydrogen.
Connecting remote regions with smaller aircraft
is particularly important in Scandinavia –
so the potential for gaseous hydrogen is huge.
In the Green Corridor project, we are working
on a direct connection between Hamburg and
Rotterdam. The airport there is involved in the
Read more about the Hydrogen
Aviation Lab on pp. 60–63 in the
ZAL FUTURED Magazine 2023.
DIEHL AVIATION
22
Robert (right) is filling
the mold – a key step
in the recycling process
for fiberglass panels.
“HAVE THE COURAGE
FOR NEW IDEAS!”
When an airplane is decommissioned, essential
parts are mostly scrapped. And this
means valuable resources are lost. The innovation
team of Diehl Aviation wants to put an
end to this. At ZAL (Center of Applied Aeronautical
Research) in Hamburg, the team is
collaborating with universities in the Free
Hanseatic City to develop solutions that optimize
the recyclability of future aircrafts. The
most recent example is a solution explored in
a master’s thesis on recycling aircraft panels.
Panels in an aircraft are used as side walls lavatory
walls, and galleys. Their lightweight design
is ideal for aviation. However, the composite materials
used are costly to recycle. Robert Langer,
master’s student at the Hamburg University of
Applied Sciences (HAW), has dedicated his thesis
to reimagining what’s possible.
LESS IS MORE
“Partitions currently consist of about ten different
materials,” Robert explains. These include an
aramid paper honeycomb structure and a reinforcing
resin system on the inside, with pre-preg
fiberglass layers on the outside. And insertion or
attachment points made of laminated fabric,
adhesive, aluminum or plastics are attached at
“HAVE THE COURAGE FOR NEW IDEAS!”
various places to provide more stability at selected
locations. Conventional recycling requires
separating these materials, which is both expensive
and inefficient. “That’s why we’d like to concentrate
on fiberglass, honeycomb and resin,
which can be reused later in the recycling process
as raw materials in the production of new
panels.” Florian Zager-Rode, an innovation expert
at Diehl Aviation and an advisor for the master’s
thesis, adds: “The goal is a complete recycling
process where no material is wasted.”
As part of his work, Robert has developed the
simplest possible recycling process for fiberglass
panels: old fiberglass components are
shredded and formed into new parts using resin
– similar to how pressboard is made from
wood chips. “In doing this, we’re experimenting
with various parameters. How finely should the
starting material be shredded? How high can the
percentage of resin be? And how strongly should
the recycled material be compacted afterwards?”
Through numerous test series, the team
has created 30 different variants.
AN IDEAL PARTNERSHIP
Most of the work takes place at ZAL – either in
Diehl’s own laboratory or the ZAL workshop. Florian:
“The collaboration with the ZAL was a real
plus. To press the test plates, Robert built his
own tool; the ZAL workshop provided the material
for this within two days. The shop foreman
was always available to Robert for support,
which was also extremely valuable.” Additional
support came from HAW, where Robert studies.
The university provided the shredder and the
testing machines for bending and tensile tests,
among other things. “This significantly reduced
costs and efforts of the tests.”
reduction. ”The recycled material could also be
used to create templates for producing other
components.
FAR BEYOND AVIATION
Robert is pleased with his nearly completed research.
“I had a real ‘a-ha moment’ during the
ZAL Science Slam when I presented my project.
Many people told me afterward how important
they felt the topic was, because fiberglass recycling
remains a challenge in many industries.
Florian adds: “Even our structural engineers
were skeptical about whether the recycling
would work as proposed. We have showed them
that it likely will! That’s the best part of pure research:
You can have the courage to just try
things out.” And thanks to his humorous presentation,
Robert even won second place at the
Science Slam.
And this is just the beginning. Diehl Aviation is
already planning another master’s thesis in
which more precise mixture ratios will be tested.
This will provide the foundation for studying
specific use cases and industrial production.
Florian concludes: “Diehl is committed to advancing
recycling – and with great partners like
ZAL, it’s an exciting journey.”
CONTACT
Florian Zager-Rode
florian.zager-rode@diehl.com
23
And the result was encouraging. Robert notes:
“Recycling is possible in principle, but many
questions still need clearing up.” The team is
already thinking about potential applications.
For example, the recycled material in the partitions
can replace the peripheral closure or reinforce
inserts in partition. “This is doubly advantageous,
offering the added benefit of weight
Testing a tensile specimen to see whether it withstands the desired load.
ESPLORO PROJECTS
THE PERFECT PIE:
NATIONAL INTERESTS
AND EUROPEAN
COLLABORATION
However, internal growth alone is insufficient.
Collaboration does not reduce our share of the
pie; it enlarges it by adding more diverse ingredients.
Complex challenges like developing
low-carbon technologies demand cross-national
capabilities and become surmountable through
collaboration.
24
Discussing how to break down large challenges so that they can be
tackled with compact solutions.
Learn more about
esploro here.
In today’s complex global landscape, challenges
like economic instability and geopolitical
tensions shape national priorities. In
response, leaders focus on internal interests,
strengthening their economies and
addressing domestic issues.
Aeronautic research reflects this principle, with
nationally funded projects like Germany’s LuFo
enhancing national expertise, creating jobs and
improving well-being. Such measures are indispensable
in uncertain times. Without a solid basis,
there is no pie to share – or, at best, a pie
without filling, unable to compete globally.
The Clean Aviation project FASTER-H2 illustrates
this. Focused on hydrogen-powered aircraft
technologies, it is jointly led by partners from
Germany and Spain with 31 beneficiaries.
esploro projects supported a balanced proposal
elaboration and continues now as project beneficiary
to ensure dissemination, communication
and exploitation (DCE). This allows partners
maintain clear rights and benefits, enhancing everyone’s
share of the pie.
Sustainability, a global challenge, cannot be
solved by one country alone, especially in aviation.
SMR ACAP work package 3, led by esploro
projects and DLR, unites partners from seven
countries to develop the Clean Aviation Aerospace
Unit Inventory Database and conduct life
cycle assessments. This supports the net-zero
emissions goal for 2050 by integrating environmental
evaluation into design processes. Such
initiatives demonstrate how collaboration drives
innovation and sustainability.
While nations must prioritize their citizens’
well-being – akin to a baker preparing tools –
they must also value cross-border collaboration.
National growth and global sustainability are
complementary, not contradictory.
THE PERFECT PIE: NATIONAL INTERESTS AND EUROPEAN COLLABORATION
CONTACT
Carsten Dörgeloh
carsten.doergeloh@esploro.com
ESPLORO PROJECTS: WHERE NATIONAL
STRENGTH MEETS EUROPEAN UNITY
At esploro, we help balance national interests
with European collaboration, crafting the perfect
pie. We enable partners to focus on their
strengths by providing technical and administrative
guidance. Fully utilizing each partner’s capabilities
and guiding them through complex projects
grows the collaborative pie, while enriching
its filling. Together, we demonstrate that working
across national, cultural and scientific borders
elevates innovation and progress.
The esploro projects team: Ayla Dörgeloh, Carsten Dörgeloh, Maria Wolff,
Ben Newman, Ingrid Pech, Daniel Schmid (clockwise).
Our team embodies this balance and cultural
complexity. Comprising a diverse mix of age, disciplines,
nationalities and genders, we contribute
a wealth of perspectives and strengths.
Guided by our values – down to the point, reliable
and concise – we address challenges from
multiple angles ensuring effective and impactful
solutions.
DISSEMINATION, COMMUNICATION AND
EXPLOITATION IN COLLABORATION
Effective collaboration requires sharing and protecting
results and knowledge. esploro projects’
DCE activities turn technical advancements into
accessible, protected information. For example,
the first UP Wing thematic workshop, hosted by
esploro, united project partners and the broader
scientific community. Experts presented and
discussed across domains and networked, identifying
key research areas and shaping future
projects and demonstration activities.
Through workshops, conferences and digital
campaigns, we showcase the achievements of
projects like FASTER-H2, SMR ACAP, UP Wing
and ODE4HERA, fostering transparency, trust
and future cooperation. By leading dissemination
efforts, we ensure that the pie we bake together
is shared widely. Communication adds
the glaze that makes the pie more appealing
and accessible.
A RECIPE FOR SUCCESS
The key to success lies in blending national focus
with international cooperation. The Clean Aviation
projects demonstrate how collaboration expands
possibilities, addressing global challenges,
driving technological advancements and building
a resilient future for aviation and beyond. Working
together ensures that our collective pie
grows larger and more fulfilling for all.
Watch the videos
to learn more about
the projects.
Stay up-to-date
on projects and
esploro news.
25
Connecting Europe’s
aerospace ecosystem
With offices in Bremen, Hamburg and Toulouse,
esploro connects stakeholders across Europe’s aerospace
hubs. Complementing this, esploro spaces foster
collaboration through tailored co-working spaces
and meeting rooms designed for the aeronautic community
in ECOMAT Bremen.
esploro spaces GmbH co-working space at ECOMAT Bremen.
AKKODIS
26
Akkodis’ Green & Fly zero-emission aircraft concept.
TRANSFORMING
AVIATION FOR A
SUSTAINABLE FUTURE
CONTACT
Nicolas Bonnotte
nicolas.bonnotte@akkodis.com
Aviation is experiencing a robust recovery
from the COVID-19 pandemic, yet this resurgence
brings significant environmental
challenges, as the sector accounted for
over 2 percent of global energy-related CO 2
emissions in 2021. With the number of air
passengers expected to double in the next
two decades, aviation emissions are projected
to rise sharply. To address this issue,
the industry is focusing on various improvements,
including advancements in
aircraft design, manufacturing processes
and air traffic management. Innovations
such as digital twins, AI-driven quality control
and the Internet of Things are transforming
manufacturing, while new propulsion
systems and Sustainable Aviation Fuel
(SAF) are being developed to reduce fuel
consumption and emissions.
In addition to technological advancements,
smarter air traffic operations can aid carbon reduction
through enhanced flight planning and
energy-efficient practices at airports. The aviation
sector is also exploring economic mechanisms
like emissions trading and offsetting
schemes to mitigate its carbon footprint. As the
industry moves forward, integrating hydrogen -
TRANSFORMING AVIATION FOR A SUSTAINABLE FUTURE
powered, hybrid-electric and fully electric aircraft
technologies will play a crucial role, although
current limitations mean these solutions
are primarily viable for short-range flights in the
near future.
GREEN & FLY
As a tech frontrunner in aviation, Akkodis is
committed to the green shift and, in 2021, first
revealed its zero-emission concept for regional
flights, named Green & Fly. This 100 percent
electric hydrogen-powered aircraft showcases a
strong commitment to scaling up renewable
energy and aiding the decarbonization of the
aviation industry through technology and innovation.
Designed with a rhombohedral wing
shape, it can carry up to 30 passengers over a
range of 500 km. Green & Fly serves as a zero-emission
regional transport alternative
aimed at enhancing mobility in mid-sized cities
without large hubs, and its Short Takeoff and
Landing (STOL) capability allows it to operate on
existing aerodrome networks, utilizing underused
infrastructure.
The concept combines the latest technologies
and explores various configurations to optimize
the aerodynamic performance and energy consumption
of the aircraft, as well as its electrification
potential. Green & Fly is a light and small
aircraft (classification CS25) with a futuristic design
and a sophisticated mechanism powered by
hydrogen fuel cells, batteries and supercapacitors
within a well-balanced hybridization strategy.
To minimize energy loss, parts of the powertrain
use superconductive materials in a clever
combination with the deep cold hydrogen.
The cockpit integrates digital applications and AI
to enable single-pilot operations. The aircraft design
features an energy recovery landing gear
with electric extension and retraction, replacing
hydraulic components with electromechanical
systems. Additionally, the wheels are accelerated
to the target speed before touchdown, reducing
particulate matter and eliminating the black
clouds of dust that were once visible from afar.
Since 2022, Green & Fly concept development efforts
have incorporated the use of “digital twin”
technology. By integrating all available data into
a virtual model, Akkodis’ experts can test metrics
such as thermal load digitally and with significantly
less effort. In the meantime, the digital
image has been further developed and provides
valuable parameters for hybridization.
The Green & Fly concept aims to inspire the
aerospace industry and challenge Akkodis’ engineers
to rethink innovative air transport, motivating
tech experts while highlighting the sector
as a key destination for talent amid intensifying
competition for skilled workers. Akkodis seeks to
address these challenges by fostering a culture
of innovation and building digital skills both internally
and externally, with Green & Fly serving
as a crucial building block in shaping the future
of the aerospace industry.
Find out more
about Akkodis.
27
The rhombohedral wing shape, compared to a
classic wing shape, generates less turbulence at
wing extremity allowing a significant reduction in
drag, opening up new possibilities for a highly
efficient propulsion system. The stiffening of its
structures is inspired by biomimicry based on
the growth process of a leaf’s veins to improve
stiffening efficiency, reducing the mass of the
aircraft. To maximize the utilization rate, the
cabin design is flexible allowing the aircraft to be
easily converted from passenger to freighter. The Green & Fly prototype showcased at ILA Berlin 2024.
DLR INSTITUTE OF MAINTENANCE, REPAIR AND OVERHAUL
THE GO-TO PLACE
FOR MRO RESEARCH
28
Rebecca Rodeck, Head of the Maintenance and Repair Technologies department, Andreas Wilken, Laboratory Manager on the left, and Philipp Czogalla,
Communications Manager, meet up in the new Project Lab.
PHILIPP We’re standing in the middle of the
new Project Lab and I can’t help but notice
you both look pretty happy.
REBECCA It was a lot of work, but I’m very happy
that we had the chance to build up this great
lab infrastructure that will support us in our research.
ANDREAS There’s certainly a sense of achievement
to have accomplished something big, and
of course I’m looking forward to future research.
The Project Lab appears to play a central
role among the new facilities. Can you
break down the structure for us?
ANDREAS Indeed, the Project Lab functions as
the center of our experimental research. It provides
test cells for a variety of projects. The other
laboratories are more specific. The Vision Lab
is aimed toward integrating people into digitalized
processes. The Measurement Lab provides
a quiet environment for complex examinations.
In addition, we have a Workshop that
supports our mock-ups while our hall area gives
us plenty of space for the new MRO Living Lab.
All in all, our institute now has five laboratory areas,
which together constitute the Application
Center MRO.
CONTACT
Dr. Rebecca Rodeck
rebecca.rodeck@dlr.de
Can you briefly explain the idea behind this
research facility?
REBECCA The Application Center MRO is a facility
for the practical research of MRO technologies
and processes. Our main research areas in
THE GO-TO PLACE FOR MRO RESEARCH
the lab are the human-machine-integration, new
maintenance approaches as well as technologies
for MRO and inspection. The Application
Center MRO gives us the opportunity to work on
real, physical components and equipment.
In our digital world – why do we need physical
components to do research?
ANDREAS Physical mock-ups allow us to study
complex systems either in isolation or under simplified
conditions. Research in real environments
would be much more difficult due to strict regulations
or limited availability. Also, digital models
cannot fully replicate the interaction between humans
and devices. That’s why we are planning to
set up an MRO Living Lab in our hall area.
Please explain the MRO Living Lab – that
seems to be due to become one of the Application
Center’s highlights.
REBECCA The MRO Living Lab consists of a small
business jet that, while not being airworthy anymore,
is fully functional. The actual procurement
of the jet is currently underway. It will provide
us with a realistic testing environment. In
addition to that, we will equip the hall area with
technologies such as a 3D tracking system to allow
research of maintenance in a smart hangar
environment.
What makes the Application Center MRO
unique?
ANDREAS The MRO Living Lab by itself is already a
very unique research facility. What makes this
even more special is the unparalleled combination
of the different, aforementioned technologies for
MRO with a living lab. Moreover, it is one of only
very few research infrastructures worldwide that
are dedicated exclusively to MRO research.
What can DLR’s partners expect from the
new facilities?
REBECCA The different lab areas all stand for
themselves, but can be combined whenever
necessary. This provides us with much higher
capacities than before. For us and our partners,
the Application Center MRO provides easy and
fast access to practical MRO research with a
high flexibility regarding the different research
topics and technologies. The MRO Living Lab
helps us to do research on a higher TRL level, as
it enables us to validate and demonstrate technologies
and processes in a relevant environment.
It essentially closes the gap between research
in a laboratory and demonstration in an
operational environment.
Please give us an idea of how the industry
is collaborating with the institute.
REBECCA There are different ways in which the industry
is already collaborating with us. We are
working on joint third party-funded research projects,
for example LuFo and EU projects. We also
have some cooperations where both partners
agree to work together on a common research
topic. Another way to work together is for the industry
partner to task us with a direct order.
What are you looking forward to the most
when it comes to the new Application Center
MRO?
ANDREAS Honestly? We finally have room to
breathe and can do more or less justice to all
the research topics we are aiming for. With our
new laboratories, we have now laid the foundation
for collaboration with partners from science
and industry.
How can folks outside keep up and get in
contact with you?
ANDREAS Just visit us or let’s meet up for coffee
– ZAL offers an excellent environment for
getting together.
Philipp Czogalla, the institute’s Communications
Manager, is looking forward to showcasing more of
the Application Center MRO this year.
Visit the institute’s
LinkedIn channel.
Visit the Application
Center MRO’s website.
29
DLR INSTITUTE OF MAINTENANCE, REPAIR AND OVERHAUL
EVERY LAB
COUNTS
CONTACT
Andreas Wilken
andreas.wilken@dlr.de
In July 2024 the Institute of Maintenance, Repair and
Overhaul moved to new premises inside ZAL. These expand
the possibilities for practical research into aircraft
maintenance. The Application Center MRO now
covers four laboratory areas and a hall area totalling
approx. 660 m². It will be extensively expanded in the
coming months.
MRO LIVING LAB
30
The MRO Living Lab embodies
the “Hangar of the Future.” It
will utilize a functional aircraft
scheduled to arrive later this year to explore cutting-edge
technologies for maintenance and modifications
under real-world conditions. Key innovations will
include robotics, IoT, AR/VR and other digitalization and
automation technologies, driving efficiency and precision.
By focusing on an operational aircraft, our team ensures
testing in a realistic environment, paving the way
for practical solutions in the aviation industry.
Simon Beckmann and Hendrik Meyer.
PROJECT LAB
The Project Lab with its flexible
space and infrastructure is
mainly used for research activities
that are closely related
to hardware. Here, the new MRO demonstrators are
qualified for the next TRL before the technologies are
tested in the MRO Living Lab. This includes, e.g., the operation
of small NDT test benches, essential mechatronic
development work and an Industry 4.0 simulation environment.
Another key element of the Project Lab is our
brand-new fleet of four industrial robots.
Florian Heilemann.
EVERY LAB COUNTS
VISION LAB
Our lab is a space for human-focused
research where
we shape new MRO technologies
with and for users. It enables
us to conduct user studies and workshops that
help us understand the human role in applied MRO processes.
The tracking area for object pose detection provides
the means to develop assistance systems, for example,
with virtual and augmented reality. Localized
eye-tracking glasses and tactile gloves allow us to examine
and design future applications.
Thore Keser and Rahel Schmied-Kowarzik.
MEASUREMENT
LAB
The lab focuses on the development
of non-destructive
testing and structural health
monitoring methods as well as sensor application. It is intended
to be available for preparing and carrying out
measurements that require a quiet environment. Current
research projects deal with the detection, localization and
characterization of structural anomalies, using machine
learning and strain data. Others benefit from thermographic
inspection and vibro-acoustic piezo sensors.
31
Philipp Conen.
WORKSHOP
Our new Workshop enables
us to quickly construct and
modify our experimental setups
used in the Project or
Measurement Lab, enhancing speed and flexibility of our
research. For me, having materials at hand and being
able to execute every necessary step with proper machinery
and in one place is the real benefit of the new
workshop. FDM printers and the integrated and extended
electrical workshop provide additional capabilities to
produce custom hardware for novel MRO applications.
Johannes Halbe.
IMPULSES & OUTLOOK
32
HAMBURG UPDATES
GREEN AVIATION
ROADMAP
Hamburg is at the forefront of transforming
the aviation industry, aiming to make air
travel climate-neutral by 2050. With its updated
Green Aviation Technology Roadmap,
Hamburg is leading the charge in reducing
aviation emissions and promoting green
technologies. An updated roadmap, a revision
of the original 2020 document, outlines a
comprehensive approach to achieving significant
sustainability milestones in aviation.
aviation, fully aligned with the objectives of
the European Green Deal. The partnership focuses
on identifying key areas of research and
innovation where Hamburg will concentrate
its efforts, ensuring targeted advancements in
sustainable aviation technologies.
The Hamburg-CA JU joint strategic roadmap is
integrated in this update of the Green Aviation
Technology Roadmap.
Find out more
about Clean Aviation.
The foundation for this roadmap update was
laid last year in 2024 with the signing of a
Memorandum of Cooperation (MoC) between
the Free and Hanseatic City of Hamburg and
the Clean Aviation Joint Undertaking (CA JU), a
private-public partnership and leading EU research
and innovation program for sustainable
and climate-neutral aviation. Through
this agreement, both parties committed to a
joint strategic roadmap for achieving net-zero
KEY AREAS
The updated roadmap is fully aligned with
CA JU’s Strategic Research and Innovation
Agenda (SRIA) that was revised in 2024. Building
on previous research performed, it aims
for a 30 percent reduction in greenhouse gas
emissions from regional-range and short-tomedium
range (SMR) aircraft. It prioritizes
three key technological pillars (also covering
areas going beyond CA JU’s scope):
HAMBURG UPDATES GREEN AVIATION ROADMAP
“A hydrogen ecosystem has huge
potential for industry and also for
aviation. The goal of green aviation
is not a distant dream, but a commonly
envisaged future. The roadmap
sends a clear and supportive signal
towards establishing this.”
Senator Dr. Melanie Leonhard, Minister of Economy and Innovation in Hamburg
• Hybrid-electric regional aircraft, including the
topics of urban air mobility, thermal management,
manufacturing processes and service life.
• Hydrogen-based technologies enabling hydrogen-powered
aircraft, including the topics
of logistics, storage and the development of
a reliable and safe hydrogen infrastructure.
• Transversal areas, including the topics of training
concepts and AI-driven intelligent assistance
systems for production and maintenance.
A major step toward implementation is the development
of a hydrogen energy systems
demonstrator for aircraft. This initiative will
serve as a key pilot project, providing valuable
insights and driving forward technological advancements
within the Hamburg Aviation
community. Another focus will be on the Hydrogen
Aviation Lab, which will enable technical
demonstration of hydrogen technologies in
aircraft and airport infrastructure.
HAMBURG’S STRATEGIC FOCUS
The Hamburg roadmap focuses not only on
driving technological progress, but also on ensuring
that these approaches are practicable
and cost-effective. The goal is to strike a balance
between technological potential, financial
resources and the need for quick, tangible results.
Additionally, the roadmap focuses on
creating sustainable aircraft designs. These include
zero-emission aircraft systems, lightweight
modular cabin designs and optimized
operations that reduce emissions both in flight
and on the ground. The integration of hydrogen
and sustainable aviation fuels (SAFs) in airport
operations will also make airports more
sustainable and reduce their carbon footprint.
CONCLUSION
Hamburg’s Green Aviation Technology Roadmap
is a bold and comprehensive strategy
that positions the city as a leader in the transition
to climate-neutral aviation. Through innovations
in hydrogen-powered aircraft, sustainable
aircraft designs and green airport
operations, the roadmap offers a clear path
towards reducing emissions, advancing clean
technologies and ensuring a sustainable future
for the aviation sector. The implication of
the roadmap also forms the basis for participation
in European funding programs through
a harmonized alignment of local and European
flagship initiatives such as CA JU and setting
an example for other cities and regions to follow
in the quest for greener air travel.
Details on the Strategic
Research and Innovation
Agenda of Clean
Aviation.
CONTACT
Dr. Christoph Heß
christoph.hess@zal.aero
33
DLR INSTITUTE OF ENGINEERING THERMODYNAMICS
34
Jannik Holtorf (left) and Markus Schorr (right) are keen: design and construction of DLR‘s new test rig are almost complete.
Next phase: commissioning.
DLR’S MULTI-STACK
TEST RIG FOR
HYDROGEN AVIATION
CONTACT
Dr. Syed Asif Ansar
syed-asif.ansar@dlr.de
A new fuel cell experimental test rig capable
of operating multi-stack architecture
was developed at the DLR Institute of Engineering
Thermodynamics as part of the
“Scalable Fuel Cell Systems for Electric Propulsion”
(SKAiB) project under the aviation
research program LuFo VI-2 of the Federal
Ministry for Economic Affairs and Climate
Action (BMWK). Led by Airbus Operations
GmbH, the project aims to scale existing
technologies for low-emission electric propulsion
systems based on fuel cells into
the megawatt range for usage in commercial
aircraft.
In contrast to previous approaches, the focus of
the new test rig is not only on the performance
of individual proton exchange membrane fuel
cell stacks (PEMFC), but also on the interaction
in complex, realistic systems under varying op-
DLR’S MULTI-STACK TEST RIG FOR HYDROGEN AVIATION
“One challenge during the design phase
was to identify the components that can
be shared between both stacks without
sacrificing system performance.”
Dr. Syed Asif Ansar, Head of Department Energy System Integration
erating conditions. An additional distinctive feature
of the demonstrator is the use of two equalsized
PEM stacks, to create a multi-stack fuel cell
system (MFCS). This approach enables the scaling
of system performance beyond available
performance of a single stack and also offers the
potential to improve the redundancy and operation
of the fuel cell system.
Both stacks of the MFCS are partly supplied by
the same balance of plant components. For example,
only a single compressor is planned to
supply the stacks with the necessary air flow for
the reaction in the fuel cells. This system design
makes it possible to increase the power density
of the MFCS by deliberately avoiding the dupli-
cation of components. However, this is linked to
increased system complexity, a challenge that
can be overcome through the use of sophisticated
control strategies.
A major part of the investigations on the MFCS
demonstrator is therefore the development, implementation
and optimization of such control
algorithms in order to ensure efficient and stable
operation. As researchers are able to study
the cross-couplings between components and
controllers as well as the dynamics of the involved
processes, the new test rig enables the
development of innovative solutions to enhance
system performance and reliability in future fuel
cell-based propulsion systems.
Read more about DLR
Institute of Engineering
Thermodynamics,
Department Energy
System Integration.
35
Discussing the placement of the shared balance of plant
components for undistorted measurements.
A view at both PEM fuel cell stacks of the demonstrator.
DLR INSTITUTE OF SYSTEM ARCHITECTURES IN AERONAUTICS
OPENING THE ROOM
FOR A NEW ERA
IN AVIATION
36
CONTACT
Dr. Björn Nagel
bjoern.nagel@dlr.de
Change is in the air and the future of aviation
can literally take many shapes. Aircraft
needed to meet two main requirements:
performance and profitability. All
the different stakeholders’ needs made it
clear that a new era is taking off. Aircraft
should be profitable for the industry, yet
become sustainable across its entire lifecycle
at three different levels – aircraft, fleet
and air transport system. With a rising demand
for flights worldwide, affordability
for the individuals is key. Challenging
enough? Maybe, but the clock is ticking …
CHALLENGES & OPPORTUNITIES
“In the next few years, the industry must take
major decisions on how to move forward. That’s
a stretch, but doable,” says Björn Nagel, Director
of DLR’s Institute of System Architectures. “There
are still many unknowns and the devil is in the
details, but we’ve got quite a few ideas,” he adds
with a twinkle in his eye.
NO SILVER BULLET – BUT PLENTY OF IDEAS
“DLR researchers agree that there’s no silver
bullet. Instead, they explore various technological
options. With 54 institutes, we can explore
future aviation in breadth and depth – from energy
production paths to aircraft architectures,
operational scenarios and more ... Our institute
specializes in digital methods, cabin and industrialization,
and new aircraft architectures.” This
is why this institute is leading two of DLR’s flagship
projects, EXACT and ALICIA, which are
closely linked.
EXACT & ALICIA:
THE BIG PICTURE, IN DETAIL
“EXACT is the largest study on sustainable aviation
to date, exploring the most promising future
aircraft in terms of economic viability and
environmental friendliness. In ALICIA, scientists
integrate these results in a digital simulation
framework, supporting politics and industry in
making informed decisions by forecasting the
impact of technologies or policies.”
GLOBAL COLLABORATION
FOR SUSTAINABLE AVIATION
“Both aviation and global warming are … global,”
says Nagel. “That means we’re in it together. As
a major research institution, our role is to bridge
academia and industry. We really want to join
forces with them and the other players such as
SMEs, start-ups and think tanks, too. That’s why
we actively seek dialogue, like through our annual
symposium ‘Architecting Future Aviation.’”
A DIGITAL HANGAR: OPEN DATA FOR ALL
“And we are thrilled that our institute is literally
opening up another room for discussion and further
research – or rather a hangar,” he adds. “In
our digital hangar, we show the world what revolutionary
aircraft like the ones from EXACT could
look like – with detailed technical data. We also
want experts to be able to get an idea of how
their technologies or components could be integrated
and what they think of our approaches, so
that we can all progress as quickly as possible.”
While the hangar currently features only a few
aircraft configurations, DLR’s research doesn’t.
“We plan to update the hangar regularly and include
unusual-looking aircraft or technologies
we’ve explored but don’t currently consider the
best options.”
OPENING THE ROOM FOR A NEW ERA IN AVIATION
Two of Nagel’s colleagues discussing EXACT hydrogen aircraft concept in CPACS format.
37
CPACS: THE LANGUAGE OF AVIATION
That would be reason enough to celebrate, says
Nagel. Another reason is his “baby” CPACS (Common
Parametric Aircraft Configuration Schema),
which turned 20 in the year 2025. It can be considered
a standardization language that is spoken
and understood by all the different disciplines
(and engineers!) in aviation, regardless of
their background (aerodynamics, structures,
propulsion).
being in Hamburg,” Nagel explains, “it’s the
world’s third largest civil aviation hub: we are
shoulder to shoulder with key European aviation
players, from research to manufacturers, airports,
operators and maintenance companies.
It’s a great place to create tomorrow’s aviation
today and help re-industrialize Europe”.
Take off to
future aircraft!
“I was involved in it and still have the paper
script from that time, long before my institute
was founded,” he says with pride. “It’s key to our
successful digital integration and optimization
of all requirements, technologies and specialized
tools – and helps keep the human in the
loop. Getting everyone to want to be part of the
big game was one of the toughest challenges.
But we got good at that, too.”
HAMBURG: A HOTSPOT
FOR THE FUTURE OF AVIATION
“We use CPACS not only in our own research
projects, but also in joint projects with industry
and academia. And that’s the great thing about
Digital hangar: DLR publishes future aircraft concepts
with complete data for open use.
DLR INSTITUTE OF SYSTEM ARCHITECTURES IN AERONAUTICS
Meeting between Pina
Donelli (DLR) and Cahide
Özkan (Airbus).
38
FAST, FLEXIBLE AND
FUTURE-ORIENTED:
THINK AHEAD, SUPPLY
CHAIN IN MIND
CONTACT
Luca Boggero
luca.boggero@dlr.de
It seems like a mission impossible: future
aircraft must be environmentally sustainable,
affordable to fly, profitable and thus
market competitive all at once. If aircraft is
to meet these demands, novel technologies,
speed, flexibility and security (against
external threats) are crucial. Aircraft largely
consist of components and parts (systems)
bought off specialized suppliers
around the world after the completion of
the aircraft design.
MAKE-OR-BUY
This approach can however lead to unforeseen
production issues, the inability to adapt to possible
market changes, an increase in costs (so
less affordable and profitable) or a less valued
end product (quality decrease). This is why aircraft
manufacturers (OEMs) need to take the
right “make-or-buy” decisions and value vs. cost
trade-offs. Which parts can – or should be – built
in-house, which components or parts should be
bought off (which) suppliers with a specialization
in this field only? But to predict which trade-offs
and decisions will have been the right ones in
hindsight seems impossible.
THREE AT ONCE: SUPPLY CHAIN,
MANUFACTURING AND AIRCRAFT DESIGN
Or maybe not. What if we managed to anticipate
and include already at the beginning those decisions
that are usually taken during the produc-
FAST, FLEXIBLE, AND FUTURE-ORIENTED: THINK AHEAD, SUPPLY CHAIN IN MIND
tion phase? Or put differently: why not find a
concurrent approach for product (aircraft) design,
supply chain and manufacturing, like it is
already being done in the car and space industry?
The DLR Institute of System Architectures in
Aeronautics is exploring this in several research
projects, while collaborating with aircraft manufacturers
such as Embraer and Airbus as well as
with suppliers like GKN/Fokker.
DIGITAL ENGINEERING IS KEY:
MEET KING VALUE, THE INTEGRATOR
To make this work and create the aircraft that
best meets all the needs, a clear and well formalized
methodology is needed. For simultaneously
optimizing highly complex aircraft, manufacturing
processes and supply chains, digital
engineering is the way to go. It is essential even,
if the aircraft design, manufacturing and supply
chain should be modeled and integrated into
one “big system” concurrently. But of course, as
it is always the case when different players are
involved, there are different views, needs and
perceptions to “problems.” This is why everyone
has to decide which criteria they value higher
than others with a sort of credit system of sorts.
This is the basis of the value-driven methodology
that the DLR institute developed: criteria can
be traded, architectural alternatives can be
ranked according to their value, supporting decision-makers
in taking design and production
choices. Consequently, obstacles or threats
down the supply chains, predictions of at what
point costs or quality could increase or decrease
and for which reasons, etc., can all be integrated
into one automated digital framework.
In the end, this digital engineering approach enhances
collaboration, aerospace companies
(OEMs and suppliers) can take decisions that
consider production constraints and supply
chain factors already in the early design phases.
In this way, more competitive, sustainable and
leading-edge aircraft can be developed.
UP NEXT: INCREASED TECHNOLOGY READI-
NESS AND LARGE-SCALE IMPLEMENTATION
The next step DLR is taking is to develop these
methodologies further to higher Technology
Readiness Levels (TRL) like in DIMENSION and
applying them on a larger scale. These efforts
will refine concurrent design practices and aim
to formalize them for broader industry application,
considering even more aspects like certification
and maintenance.
Research projects
on value-driven
concurrent approach
AGILE 4.0 (EU Horizon 2020)
Implementation of an integrated cyber-physical aeronautical
supply chain, including design, production, certification and
maintenance, leading to innovative and more sustainable
aircraft products. Initial development of the value-driven
model-based methodology.
Scope: Identification of the best solutions
for the horizontal tailplane of an aircraft
considering the design, manufacturing and
supply chain.
Industrial partners: Embraer, GKN/Fokker
Learn more
about AGILE 4.0.
39
Discussion about the design and supply chain of the
aircraft door.
DIMENSION (LuFo Germany)
Development of new door architectures for passenger aircraft,
with them being one of the most complex aircraft components.
Mastering its design and corresponding production process simultaneously
promises to be very beneficial for future aircraft
programs.
Scope: Exploitation of methodology extended to safety, maintenance
and risk assessment: identification of the best solutions
for door components (hinge arm and latching system).
Industrial partner: Airbus
JETLITE
Measuring daylight exposure on
board of an Airbus A33.
40
A SCIENCE- DRIVEN
VISION
Find out more
about Chronolite.
CONTACT
Dr. Achim Leder
pr@jetlite.com
Find out more
about FAIRcraft.
At jetlite, we know that lighting is more
than just illumination – it’s the key regulator
of the inner clock, supporting well-being
and performance. Many people already
know jetlite for its cabin lighting solutions
designed to reduce jet lag. However, continuous
research and validation drive its innovations.
FROM SCIENCE TO APPLICATION
Think about the night shift mode on a phone. A
simple change in screen lighting can help improve
sleep by reducing blue light exposure.
Now imagine scaling that concept to an entire
aircraft, where lighting adapts to flight routes,
time zones, cabin interiors, workflows and even
individual chronotypes. That’s exactly what jetlite
does – scientifically measuring, analyzing
and optimizing lighting to support the body’s
natural rhythm, helping passengers adjust faster
and allowing crew members to stay alert and
recover better. Light is the most powerful external
factor that supports the inner clock. By adjusting
color temperature, intensity and timing,
jetlite actively helps the body adapt to new time
zones, reducing jet lag by up to three hours. But
the approach doesn’t stop there.
RESEARCH AS THE DRIVING FORCE
Innovation in aviation requires science-based
solutions. jetlite’s technology is built on onground
and in-flight studies with Lufthansa,
proving that jetlite’s lighting scenarios improve
sleep, support melatonin regulation, and enhance
well-being. But science never stands
still – jetlite continues to optimize its solutions.
In 2024, four test flights to North and South
America were conducted with customers to test
and refine cabin lighting for passenger and crew
needs.
In addition, jetlite leads the consortium of the
BMDV-funded Chronolite project. Together with
Hella, Charité, TU Ilmenau, Lufthansa Technik
and other partners, the project develops connected
lighting solutions for aircraft, trains, cars
A SCIENCE-DRIVEN VISION
69%*
melatonin reduction
was achieved right on time
to ensure activation
88%*
of passengers who usually
don’t find sleep on a plane
were able to sleep
80%*
of business class passengers
rated the flight with jetlite a
superior flying experience
* Scientific studies conducted with renowned research institutes show the positive effects of jetlite Cabin One.
and terminals to create a seamless lighting experience
along the passenger journey. Sustainability
also plays a key role – FAIRcraft, funded by
IFB Hamburg, explores new ways to make aircraft
interiors more eco-friendly through innovative
materials and cabin concepts. jetlite supported
Comprisetec and BFGF in exploring how
lighting solutions can contribute to a more sustainable
cabin design. Using ZAL TechCenter’s
labs and key partnerships with Lufthansa Technik,
SFS and TuHH, for example, jetlite continues
advancing cabin lighting – further innovating its
solutions in 2025 and beyond. Check out the
project links for more details!
jetlite aircraft mock-up in the ZAL hangar.
41
Step into the light – literally!
We believe in making artificial light better – with science-based research
and results – but let’s be honest: nothing beats natural daylight.
Sunlight is nature’s best energy booster, mood lifter and sleep
regulator. So, while we keep pushing the boundaries of cabin lighting
technology, here’s our friendly reminder: go outside! Even if the
sun isn’t shining and the sky is in its usual grayish Hamburg shade,
daylight still does its job. Take a 15-minute walk, soak up whatever
light you can, and let nature reset your inner clock. Your energy levels,
mood and sleep will thank you for it.
Measuring lighting in TUHH laboratory.
FFT
ATON automated adhesive film application and component integration.
42
AIRCRAFT PRODUCTION –
INTELLIGENT AUTO-
MATION AT EVERY PHASE
Fuselage sections of future aircraft are
versatile regarding aspects like building
principles, materials or system integration.
However, their production will be highly
automated to meet upcoming manufacturing
demands regarding time, cost, quality
and flexibility.
As part of a variety of research projects in the
frame of LuFo, supported by the German Federal
Ministry for Economic Affairs and Climate Action,
FFT together with its partners is developing production
systems for both metal and CFRP fuselage
sections that range from handling of stringers
over precise position of large components
such as doppler sheets or window frames up to
innovative joining of full-scale fuselage sections.
Thereby, in the context of an industrial utilization,
the technologies can be integrated either
into existing (brownfield) or entirely new production
lines (greenfield). The projects can benefit
from FFT’s diverse product portfolio related to
tolerance measurement and optimization (Best-
Fit, VisionView), lightweight grippers and structures
(FibreTec3D, CarbonGripper), component
transport (iGV) or digital process monitoring (FF-
Trace) as well as from FFT’s experience of more
than 50 years in the design and development of
intelligent production systems.
AIRCRAFT PRODUCTION – INTELLIGENT AUTOMATION AT EVERY PHASE
FLEXIBLE STRINGER PREFORM
HANDLING
In the DHiiP project FFT moved flexible CFRP
preforms and tool cores into a consolidation
tool for producing stringers using an RTM process.
The pick-up and handling of multi-part metallic
cores and textile preforms led to specific
requirements for the process automation, which
could be met by a combination of vacuum,
clamping and magnetic grippers. The deformability
of the flexible semi-finished products created
handling challenges in terms of placement
accuracy, which could also be overcome by the
gripper mechanism. In addition, a digital product
twin was developed and integrated into the
system control to provide data from upstream
and to downstream processes.
AUTOMATED COMPONENT INTEGRATION
A new construction method for aluminum fuselage
segments was investigated within the project
ATON, which focused on automated deposition
of adhesive-bonded doublers, window
frames and stringers. First, the adhesive film was
applied to the components. Following that, they
were automatically placed on the fuselage skin.
The adhesive application was implemented by
the project partner Fraunhofer whereas FFT was
responsible for the overall plant engineering,
technology integration and system control including
simulation and functional testing.
SECTION ASSEMBLY AND
SYSTEM INSTALLATION
A system for section assembly including system
installation was developed in the SeMoSys project.
The focus here was on a reduced assembly
time and a higher degree of automation by shifting
preparation activities outside the station and
automating the transport using FFT’s iGV, while
avoiding overhead crane operations. FFT was responsible
for the entire concept, design and realization
of the system. Presentation frames
built from FFT’s lightweight FibreTec3D profiles,
laser tracker shimmed contour blocks and a
load optimized steel frame resulted in a high positioning
accuracy. Arbitrary positioning of the
longitudinal joints allows ergonomic working
and optimal robot usage whereas replacing contour
blocks enables easy adaptation to different
shell geometries.
The tolerance concept was jointly developed
with Fraunhofer IFAM, which performed all measurements.
The partners Fraunhofer and PFW
Hutchison set up system installations like pipe
moduls. Thinking out of the box resulted in an
innovative assembly station, which enables novel
assembly processes and technologies with
parallel system installation.
More information
on FFT’s R&D
and Technologies.
CONTACT
Philipp Schwanemann
philipp.schwanemann@fft.de
43
Two cooperating industrial robots were used for
the automated, tolerance-compliant stringer
handling in a full-scale demonstration near an
industrial environment. By integrating FFT’s optical
measuring system BestFit into FFT’s Carbon-
Gripper, it was possible to implement active tolerance
compensation and meet the challenging
process requirements. A third robot on a linear
axis took care of the handling of the doublers
and window frame.
In the follow-up project GREATER the technologies
are currently further developed for spherical
components and analyzed by the project
partner Airbus Aerostructure within their R&D
facilities, since they enable significant mass reductions
and a high degree of automation.
SeMoSys assembly station.
IMPULSES & OUTLOOK
2025 IN CHARTS:
AVIATION’S
MAKE-OR-BREAK YEAR
FOR INNOVATION
44
Air travel is one of humanity’s greatest
technological achievements, connecting
people, cultures and economies across the
globe. Over the past 50 years, the democratization
of air travel has fueled exploration
and global exchange like never before.
NO DECARBONIZATION
PATH FOR AVIATION
Projected global CO 2 emissions (in Mt CO 2 )
In Announced Pledges Scenario (APS)
But this success comes at a cost. Aviation is at
a crossroads. Why? Aviation’s social license to
operate in the future is under growing pressure
as its carbon footprint expands. While
other transport sectors are making progress
to reduce emissions, aviation’s CO 2 output is
set to rise sharply.
AVIATION +47% SHIPPING +1%
1,200
RAIL –10%
1,200
0
120
0
ROAD 0%
7,500
Guest article by Lennart Dobravsky, founder
of Research+Attitude, a market intelligence
and thought leadership agency, and creator of
OneChart, a newsletter curating the most
insightful data charts in aviation and travel.
0 0
2022 2030 2022
2030
Source: Research+Attitude analysis, Sustainable Aero Lab, IEA.
2025 IN CHARTS: AVIATION’S MAKE-OR-BREAK YEAR FOR INNOVATION
EFFICIENCY GAINS CAN’T OUTRUN DEMAND
In talks with decision-makers in aviation, it’s
often argued that the chart on the left is misleading
because individual flights are becoming
more efficient, pointing to improved CO 2
per passenger mile. While efficiency gains are
real, they are nowhere near enough.
In simple terms: the industry isn’t decarbonizing
– it’s expanding its footprint. Without radical
innovation at an unprecedented pace, sustainability
progress, let alone net-zero ambitions,
remains entirely out of reach.
The uncomfortable reality: efficiency gains aren’t
keeping up with surging demand. More
people are flying than ever before, pushing total
emissions to new heights. A case in point:
2024 set a new record for the highest total CO 2
emissions in airline history.
For more insightful data charts on the future of
aviation and travel, subscribe to the OneChart
newsletter at onechart.co or scan the QR code.
EFFICIENCY GAINS ARE NOT ENOUGH
45
CO 2 per seat per mile (g)
Total airlines’ CO 2 emissions (Mt CO 2 )
153
151
149
1100
1000
900
800
700
147
145
600
500
400
143
141
139
2018 2019 2020 2021 2022
300
200
100
0
2000 2004 2008 2012 2016 2020 2024
Source: Research+Attitude analysis, Sustainable Aero Lab, IBA Net Zero, IEA.
IMPULSES & OUTLOOK
For years, aviation leaders have defended the
industry’s environmental impact with a single,
seemingly modest statistic: aviation is responsible
for only two to three percent of global emissions.
The argument goes something like this:
AVIATION’S OUTLOOK
WITHOUT INNOVATION
Aviation’s share of global CO 2 emissions given current trajectory
WHY TARGET AN INDUSTRY THAT
CONTRIBUTES SUCH A MARGINAL SLICE
OF THE ENVIRONMENTAL PROBLEM?
But that narrative is about to shift – dramatically.
• According to Boeing’s aviation emissions
models and the IEA’s APS scenario forecasts,
aviation’s CO 2 emissions will double to five
percent of the world’s total in less than seven
years.
2.5%
5%
24%
46
• If this trajectory holds, by 2050, aviation
alone will account for a staggering quarter
of all global CO 2 emissions.
The repercussions of such an escalation are
immense – and largely unpredictable.
2025
2030
(APS)
2050
(APS)
One thing, however, is certain: mounting pressure
and public scrutiny will challenge aviation’s
very essence.
Source: Research+Attitude analysis, Sustainable Aero Lab, Boeing Cascade, IEA.
This hard reality leads us to a critical question:
What can the aviation industry do to reverse
its CO 2 trajectory?
As a society, we’ll be forced
to ask: is the connectivity
and convenience offered by
aviation worth the looming
environmental calamity?
THE ONLY WAY FORWARD:
RADICAL INNOVATION
The answer can only be one thing: doubling
down on innovation.
This isn’t about marketing campaigns around
CO 2 offsetting or swapping cabin plastic cutlery
for bamboo. It’s about committing real
dollars to accelerate R&D, build new aircraft
designs, explore alternative propulsion systems,
expand SAF supply and adoption, and
maximize digitalization and connectivity to optimize
fuel savings – all at the same time!
Aviation must shape its future with unprecedented
willpower and force – or risk having
that future shaped by not doing so.
2025 IN CHARTS: AVIATION’S MAKE-OR-BREAK YEAR FOR INNOVATION
WORDS SPEAK LOUDER THAN ACTIONS
TALK
# of publicly announced net-zero commitments
by major airlines
ACTION
# of actual sustainability projects launched
by major airlines
40
35
70
60
30
25
20
15
10
5
0
+ 65%
50
40
30
20
10
0
–77%
2018 2019 2020 2021 2022 2023 2018 2019 2020 2021 2022 2023
47
Source: Research+Attitude analysis, Sustainable Aero Lab, Nat Bullard, BloombergNEF, ICAO.
THE GOOD NEWS:
2025 IS SHAPING UP TO BE DIFFERENT
According to Amadeus’ latest survey of senior
airline leaders, innovation and sustainability
have become the top two strategic priorities
for full-service carriers – outranking even financial
objectives. This does signal a major
shift: the industry may finally be recognizing its
once in-a-generation imperative to innovate.
2025 will show whether the aviation industry
will turn priorities into action – or if, once
again, words will outpace execution.
INNOVATION &
SUSTAINABILITY AS KEY
PRIORITIES FOR 2025
Most mentioned airline objectives for investments this year
Full-service
airlines
Innovation
Sustainability
0% 100%
Margin
improvement
Revenue increase
CONTACT
Lennart Dobravsky
lennart@onechart.co
Improved traveler
experience
Source: Amadeus Travel Technology Investment Trends.
ZAL GMBH
BUILT
TO LAST,
EASY TO
RECYCLE
minimizing manual labor. Thanks to semi-automation,
the production process becomes faster
and more cost-effective. And there’s more: the
printing material is over 50 percent biobased,
further lowering the environmental impact. Key
applications could include more customized
cabin designs with smaller production runs.
48
Watch the
manufacturing
process now.
Overhead Storage Compartments (OHSCs)
face tough demands in passenger service.
Travelers often forcefully shove their heavy
carry-on luggage into the compartment,
slamming the door shut with a swift push.
To withstand these and other challenges like
turbulences, OHSCs need to be stable, durable,
and securely anchored to the cabin wall. This is
achieved through a combination of honeycomb
panels, reinforcements, adhesives and brackets.
However, at the end of the cabin’s lifecycle, this
complex mix of materials makes disposal much
more difficult. But what if cabin components
could not only be light and strong, but also easy
to recycle?
THREE MANUFACTURING STEPS, ONE
SUSTAINABLE SOLUTION
RAFINESS goes beyond simple optimizations: it
addresses the entire lifecycle of a cabin component
– from production to end-of-life. This approach
could lay the foundation for a new generation
of aircraft cabins, where sustainability
and efficiency go hand in hand. And the best
part? It only takes three straightforward steps to
make this vision a reality.
RAFINESS –
Only Three
Manufacturing Steps
PRINTED BRACKETS AND REINFORCEMENTS
The RAFINESS project (Robot-guided additive
manufacturing of integrated, sustainable and
electrically conductive interfaces for cabin sandwich
structures*) takes a fresh look at overhead
bins, simplifying every step from manufacturing
to disposal. This is made possible by robotguided
additive manufacturing, where reinforcements
and brackets are printed directly in a single
step. This innovation reduces the number of
materials used – from seven to just two – while
1. Preparation of honeycomb panels by
an automated milling robot.
2. Application of potting and brackets
in one step.
3. Post-processing the brackets by
a milling robot.
Result: final RAFINESS demonstrator in
the ZAL Additive Manufacturing Lab.
CONTACT
Preety Bhargava
preety.bhargava@zal.aero
*The RAFINESS project is funded by the German Federal Ministry of Digital Affairs and Climate Action (BMWK) and the Austrian
Research Promotion Agency (FFG). Technology partners: WEBER Additive, Aibuild. Project partners: carboncleanup, FACC, Fraunhofer
UMSICHT, Fraunhofer IFAM, SFS, TCKT, Wood K Plus.
BUILT TO LAST, EASY TO RECYCLE
1.
STEP
2.
STEP
3.
STEP
RESULT
Stable connections made from a
single material – showcased at
the RAFINESS demonstrator.
49
AIRBUS
50
MFFD rollout on July 3, 2024, at ZAL Hamburg.
THE WORLD’S FIRST
THERMOPLASTIC
FUSELAGE AT ZAL
CONTACT
Ralf Herrmann
ralf.herrmann@airbus.com
On March 7, 2024, the MultiFunctional Fuselage
Demonstrator (MFFD) arrived at ZAL
and took its place in Hangar A. Within the
framework of the European CleanSky 2 research
program a partner consortium delivered
the first thermoplastic passenger aircraft
fuselage section worldwide. While the
MFFD platform itself won’t fly, its innovations
will shape future aircraft with lighter
weight and reduced production time, working
toward Airbus achieving its decarbonization
goals.
This flagship demonstrator represents a full
scale typical single aisle commercial aircraft fuselage
section made out of thermoplastic composite
materials, covering novel design and built
concepts, elementary parts manufacture for au-
THE WORLD’S FIRST THERMOPLASTIC FUSELAGE AT ZAL
Key benefits
• Less CO 2
emissions through weight reduction
• Dustless joining through thermoplastic welding
• Auxiliary material reduction through in-situ
• Process time reduction through automation
• Pre-equipped large-scale modules
Read more about
fantastic thermoplastics.
tomation as well as thermoplastic welding for
sub- and major component assembly. The consortium
of 12 European organizations led by Airbus
investigated thermoplastic composites for
large passenger aircraft fuselage applications.
More than 40 different technologies have been
developed, real size parts manufactured and assembled
considering high-rate production.
Technologies have specifically been set up in a
competitive environment to maximize learning
and push existing boundaries. This 8 m long and
4 m in diameter fuselage barrel is the world’s
first and largest R&T platform made out of thermoplastic
composite materials.
Solemnly “rolled out” on July 3, 2024, the MFFD
will serve as a vehicle for future R&T projects. It
was launched immediately after its arrival to validate
and verify the engineering and manufacturing
concepts that lie behind the progressive
approach of this flagship demonstrator. These
include modular design and built concepts,
thermoplastic elementary parts manufacturing
on various scales from small-sized clips, medium-sized
stringers and frames of up to 8 m long
fuselage skins, skin manufacture with Automated
Fibre Placement (AFP) and both autoclave
consolidation (lower shell) and out-of-autoclave
in-situ consolidation (upper shell), novel integration
processes using different thermoplastic
welding technologies on a large scale, preequipped
floor module incl. systems and a CFRP
cargo door with an innovative electro-mechanical
latch-and-lock system. More information on
the longitudinal welding of upper and lower fuselage
in the major component assembly can be
found in the article from Fraunhofer- Gesellschaft
(see page 52–53).
The MFFD consortium, led by Airbus, is very
proud that the potential of thermoplastic composites
in aerospace and thus the importance
and value of the project has been recognized by
winning the prestigious JEC Innovation Award
on January 13, 2025, in Paris for advancements
in thermoplastic composites for large-scale
commercial aircraft production. The JEC Innovation
Awards are highly competitive, with over
170 applications, and the MFFD project triumphed
in the Aerospace – Parts category.
ZAL – home of the MFFD flagship and several
partner organizations – is part of this global success
story.
Partners:
Airbus, Aernnova,
Diehl, DLR, FIDAMC,
Fraunhofer, GKN
Fokker Aerospace, NLR,
SAM XL, TU Delft, Saab.
MFFD team representatives from left to right: Juan Carlos Southwood
(FIDAMC), Ralf Herrmann (Airbus), Simon Kothe (Fraunhofer), Benjamin
Diehl (Fraunhofer), York C. Roth (Airbus), Norbert Heltsch (Airbus), Joost
Koopman (GKN Fokker Aerospace), Piet Woelcken (Airbus), Lars Larsen
(DLR) and Matthias Uellendahl (Airbus Aerostructures).
51
FRAUNHOFER IFAM
MAJOR COMPONENT
ASSEMBLY OF MFFD
52
Explore
Fraunhofer IFAM.
There is an urgent need for climate-friendly
solutions for both the production and operation
of passenger aircraft that help to
save even more resources. In addition to
new propulsion technologies, the focus is
also on structural weight and manufacturing
costs. Both can be reduced through new
construction methods, such as can be
achieved with thermoplastic CFRP materials
in particular. For the first time, a fullsize
fuselage segment was therefore
produced from thermoplastic CFRP materials
– the Multi Functional Fuselage Demonstrator
(MFFD), honored with the JEC Composites
Innovation Award 2025.
BUT WHAT DID THE AUTOMATED PROCESS
OF THE MAJOR COMPONENT ASSEMBLY
LOOK LIKE?
With its partners, Fraunhofer IFAM designed and
built the automated assembly research platform
for the MFFD, including the central system and
process control, at the CFK Nord research center
in Stade as part of the Multifunctional automation
system for Fuselage Assembly Line (MultiFAL)
project.
As work package leader, Fraunhofer IFAM was
responsible for the overall coordination of the
technology integration from the involved partners
and the design of the automation to ensure
the major component assembly process of
the MFFD.
Further tasks performed by Fraunhofer IFAM
along the process chain initially included the
picking up of the lower shell using a specially developed
fixture, which allowed the lower shell to
be aligned with high precision in the assembly
space for the subsequent processes. The upper
shell was picked up by a holding fixture consisting
of ten hexapod robots which positioned the
two shells in relation to each other with sub-millimeter
precision. In addition, the optimum
shape and position of the shells was set up with
a developed control loop using a laser sensor
and readjusted by the hexapod robots at any
time, if necessary.
The MultiFAL assembly research platform with inserted thermoplastic fuselage
shells of the MFFD at the Fraunhofer IFAM in Stade. The yellow hexapod robots are
used for holding and high-precision adjustment of the shape and position of the
upper shell.
KEY TECHNOLOGIES FOR BUTT STRAP
JOINING WITH A CONTINUOUS LASER
WELDING PROCESS
For the longitudinal joint on the left side of the
MFFD, the overall coordinator Airbus decided to
use a continuous laser welding process, and a
MAJOR COMPONENT ASSEMBLY OF MFFD
The MFFD aircraft fuselage segment after final assembly at the MultiFAL
research platform at the Fraunhofer-Gesellschaft in Stade.
The gap-filling end effector carries out the thermoplastic gap filling using
an extruder after CO 2
laser welding of the butt straps onto the fuselage
shells.
53
special kind of joint geometry was designed to
this end. In addition to positioning the shells
and compensating local deformations in the
part edges, Fraunhofer IFAM investigated further
topics necessary to enable the automated
joining process.
On the one hand it regards the handling of the
required straps that are laid up and welded into
the joint. The one-millimeter thin straps are
made of the same thermoplastic material as the
shells and have varying dimensions in width and
length. The longest strap has a length of 4.5 meters
and a changing width between 6 and 36 centimeters.
For a reliable layup process, Fraunhofer
IFAM developed a special strap handling
end effector to provide the material automatically
for the laser welding process and react to the
varying dimensions of the long, flexible parts.
On the other hand, the straps and the stepped
joining zones of the shells could not be connected
seamlessly due to unavoidable manufacturing
tolerances and the degrees of freedom required
for positioning the straps. This resulted
in small, irregularly wide gaps remaining between
them, which ran the risk of impairing the
quality of the welded joints and therefore had to
be completely filled with a so-called thermoplastic
filler after every layer. A compact gap filling
end effector contains an integrated 2D sensor
for the immediately measuring and dynamic calculation
of the local gap volume as well as an
extruder. This was guided along the previously
created joining seams to heat the initial granulate
and convey it to the gap. This meant that the
irregular gaps of three to 20 millimeters in width
were filled with the exact amount of molten
thermoplastic material. To guarantee a consistent
quality in terms of flatness for the next layers,
any excess material had to be avoided under
all circumstances.
With these technologies, Fraunhofer IFAM has
helped to ensure that the laser welding process
and thus the joining of the two shells are successfully
carried out on the MFFD.
CONTACT
Björn Reichel
bjoern.reichel@ifam.fraunhofer.de
Further information
about the
Fraunhofer IFAM
in Stade.
FRAUNHOFER IFAM
SeMoSys ring station for sectional
assembly of an aircraft fuselage with
integrated system installation at
Fraunhofer IFAM site in Stade.
54
OPTIMIZED AIRCRAFT
FUSELAGE ASSEMBLY
Watch the video
about SeMoSys.
The SeMoSys research project is redefining
section assembly in aircraft manufacturing
by accelerating process speeds and integrating
systems earlier in the sequence. A
key highlight of this initiative is the enhancement
of ergonomics through the strategic
use of automation, which boosts efficiency
and improves working conditions.
has become essential. The challenge lies in harmonizing
high production rates with stringent
quality standards. By integrating system installations
– such as supply modules with pipes and
ducts – early in the assembly process, the project
is not only streamlining operations but also
accelerating the time to market for new aircraft
models.
ELEVATING EFFICIENCY: THE FUTURE OF
AIRCRAFT ASSEMBLY
In the dynamic realm of aerospace, the research
project “Sektionsmontage mit Systeminstallationen”
(SeMoSys) led by Airbus is making waves
by redefining the sectional assembly of aircraft
fuselages sections. With the industry’s increasing
demands, optimizing production processes
THE RING CONCEPT: A BREAKTHROUGH IN
ASSEMBLY OF FUSELAGE SECTIONS
At the heart of this innovation is the advanced
section assembly concept developed in collaboration
with partner FFT. Imagine a sophisticated
ring station where component carriers are efficiently
aligned, supported by an FFT automated
and intelligent guided vehicle (iGV). This design
OPTIMIZED AIRCRAFT FUSELAGE ASSEMBLY
“SeMoSys shows new ways for floor-guided
shell transport and craneless assembly,
as well as implementation of smart toolings
and automated systems.”
Dr. Christian Kulik, SeMoSys Project Manager, Airbus
accommodates the A320 family and enables the
positioning of the three-part section using novel
component carriers that are guided and aligned
in a circular ring station – an impressive feat of
precision and efficiency. The experts at Fraunhofer
IFAM ensured tolerance compliance
during the assembly process using highly precise
measurement technology. This meticulous
planning leads to smooth workflows, paving the
way for a successful assembly process.
55
PRECISION IN ACTION: SYSTEM INSTALLA-
TION OF AIRCRAFT SUPPLY MODULES
After the assembly of the fuselage section, focus
turns to the precise installation of supply modules
of partner Hutchinson PFW. These modules
are delivered to the assembly site via an innovative,
mobile paternoster system, ensuring
smooth logistics. Installation occurs in very tight
spaces using a traverse and push chain technology,
with a strong emphasis on ergonomics for
the workforce. A successful full-scale validation
in Stade confirmed that efficiency and quality
can go hand in hand. Through these advancements,
the aerospace industry is not just adapting
but redefining competitive excellence in
manufacturing.
CAD model from SeMoSys ring station for sectional assembly of an aircraft fuselage
with integrated system installation.
CONTACT
Benjamin Diehl
benjamin.diehl@ifam.fraunhofer.de
Automated installed systems in fuselage section.
CAPGEMINI
56
DIGITAL TWINS:
BRIDGING PHYSICAL
AND VIRTUAL
WORLDS WITH XR
In an increasingly digital world, Digital
Twins are revolutionizing industries by
seamlessly connecting physical and virtual
environments. Enabled by extended reality
(XR), artificial intelligence (AI) and the Internet
of things (IoT), they provide real -
time insights, predictive analytics and enhanced
decision-making. Businesses can
optimize operations, improve efficiency
and drive innovation through these intelligent
systems.
At Capgemini Engineering, we leverage these
technologies to create transformative solutions
across industries. Advanced 3D capturing methods,
powered by mobile devices, drones and
autonomous robots, enable real-time spatial
mapping, further expanding the potential of
digital twins.
This year, we spotlight breakthroughs in 3D capturing
and digital twin technology. By integrating
XR and advanced sensor systems, we set new
benchmarks for creating dynamic, continuously
updated digital twins. These innovations enhance
decision-making, boost operational efficiency
and pave the way for smarter, more sustainable
ecosystems.
DIGITAL TWINS: BRIDGING PHYSICAL AND VIRTUAL WORLDS WITH XR
“Capgemini’s acquisition of Unity’s
digital twin professional services arm
marks a bold leap forward, accelerating
enterprise digital transformation
with real-time 3D technology!”
Andreas Kötter, Head of Research & Innovation
THE FUTURE OF DIGITAL TWIN ECOSYSTEMS
The evolution of AI, robotics and IoT is making
digital twins more autonomous and self-updating,
allowing businesses to optimize operations
effortlessly. Enhanced 3D capturing, combined
with AR and VR, is reshaping entertainment, education
and more.
However, challenges persist – high setup costs,
data management and large-scale rendering
require efficient solutions. In collaboration with
industrial and academic partners, we tackle
these issues through research on large-scale
digital twin rendering and 3D object capture
methods.
LEADING IN R&D
Capgemini Engineering advances digital twin
ecosystems through R&D projects and public -
funded consortia. We provide expertise across
industries, acting as a technology enabler. Digital
twins offer real-time data updates via IoT
sensors, accurately reflecting physical systems.
XR technologies – encompassing virtual reality
(VR), augmented reality (AR) and mixed reality
(MR) – enhance their applications across manufacturing,
healthcare, energy, aerospace and
smart cities.
TRANSFORMING INDUSTRIES
WITH DIGITAL TWINS
Digital twins of industrial shop floors enable
real -time monitoring, predictive maintenance
and optimized resource planning. Autonomous
mobile robots, equipped with SLAM (simultaneous
localization and Mapping), enhance spatial
mapping and efficiency. In aerospace, virtual IoT
maintenance systems industrialize digital ecosystems,
improving factory visualization and
training through XR-based solutions.
Sensor-integrated digital twins also optimize
urban environments, enabling smarter urban
planning, traffic management and disaster preparedness.
Capgemini’s Unity-based VR applications
provide simulations for weather forecasting,
traffic flow optimization and emergency
scenarios. Beyond urban applications, we are
exploring innovative VR integrations with MBSE
(model-based systems engineering) to push the
boundaries of simulation and efficiency.
SHAPING THE FUTURE
As industries seek cost efficiency and operational
improvements, digital twins combined with XR
technologies will drive real-world impact. By integrating
AI, robotics and IoT, Capgemini
Engineering continues to push the boundaries
of scalable, real-time digital twin solutions.
These advancements will be pivotal in building
smarter, more sustainable ecosystems and
shaping the future of industry and society. Let’s
embrace this transformation and create a more
connected world together.
Read more about
our other research
projects.
CONTACT
Andreas Kötter
57
andreas.koetter@capgemini.com
IMPULSES & OUTLOOK
58
It’s a match – the
ZAL kicker league
has been connecting
people since 2017.
“The ZAL kicker league is like
research – just faster. It’s a playful
way to learn, experiment,
observe, adjust strategies and
develop a competitive spirit.”
Simon Beckmann, Team MO-6, DLR Institute of Maintenance,
Repair and Overhaul
KICKS & COLLABORATION
How does the league work?
PATRICK Teams meet during their lunch breaks
for league matches. The league is divided into
two divisions, so there’s a place for both beginners
and more experienced players. Teams are
typically composed of members from various
companies at ZAL. This year is particularly exciting
because, for the first time, we have a
team made up of members from different
companies. It’s a great example of how easily
aviation professionals connect at ZAL around a
subject they pursue with enthusiasm.
At ZAL, collaboration and networking takes
many forms, but one of the most unique
and popular is the ZAL kicker league.
FUTURED sat down with current league coordinator
Patrick Naujoks to learn more
about this community-driven initiative and
what makes it so special.
The ZAL kicker league has become a wellloved
tradition. How did it all begin?
PATRICK Unlike many of ZAL’s other events,
which are expertly organized by our event
team, our kicker league is a grassroots effort
through and through. It was started by a member
of the ZAL community and has been growing
ever since.
Would you say that the networking happening
here influences or spreads across to
other areas?
PATRICK What is special about our kicker
league is the relaxed atmosphere. Engineers
and professionals from different companies
connect across hierarchies without the usual
formalities. It’s not just about playing; it’s
about coming together, watching, cheering,
competing, laughing a lot and sharing a common
interest – in short, having fun together.
From this, connections and relationships are
formed. And indeed, people frequently ask me
how I got to know a certain person, and the answer
is often “the ZAL kicker league!” And as
you can imagine, these connections make collaboration
on projects or the exchange of
ideas and technologies much easier.
What’s your vision for the league’s future?
PATRICK I’d love to see us expand – with more
space for the tables or a dedicated community
room someday or even more soccer tables. The
potential to connect even more people is huge.
I am sure there are amateurs who are interested
but who are currently afraid to approach the
tables because they only meet experienced
players. I think it would be easy to create a third
league. The league is about connecting people,
no matter their skill at table soccer.
59
IMPULSES & OUTLOOK
WANT TO JOIN
OR START
A NEW TEAM?
The ZAL kicker league
is open to everyone!
Currently, 16 teams are organized
into two divisions,
welcoming both beginners
and seasoned table soccer
players.
60
CONTACT
Patrick Naujoks
kickerliga@zal.aero
“People frequently ask me how
I got to know a certain person,
and the answer is often:
the ZAL kicker league!”
Patrick Naujoks, Team NP^2 and League Coordinator,
ZAL GmbH
KICKS & COLLABORATION
“For me, the ZAL kicker
league is just like working at
ZAL – it’s easy to connect,
exchange ideas and stay focused
on success, of course!”
Lisa Marie Meier, Team Knallgasbande, Airbus
61
ZAL @Silpion
Kicker Cup 2025
Over 200 teams – including many
from ZAL – will compete in the Silpion
Kicker Cup at Millerntor Stadion
this year. Register your team here to
join them, or cheer on your favorite
ZAL team as a supporter! When?
On May 9, 2025.
More info about Silpion
Kicker Cup 2025.
TECCON
HYDROGEN TAKES OFF –
SUSTAINABLY
INTO THE FUTURE
62
CONTACT
Jörg Manthey
joerg.manthey@teccon.de
Powerful, scalable hydrogen drives are crucial
for emission-free aviation. The H2 FINI-
TY research project developed this technology
for UAVs and studied their potential
application for small aircraft. A milestone
was reached with the successful maiden
flight of a hydrogen-powered UAV. The follow-up
project HYDRO-BUNNY takes these
achievements even further and enables autonomous,
sustainable hydrogen refueling
for unmanned aerial vehicles – an important
step towards climate-neutral aviation.
MAIDEN FLIGHT IN H2 FINITY: A MILESTONE
H2 FINITY, in which TECCON, mb+Partner, ZAL
and Thelsys were involved, made significant
progress with the first successful flight of their
hydrogen-powered drone on November 8, 2024.
The UAV, for which a hydrogen powertrain was
developed, proved the basic functionality of its
fuel cell propulsion system and its potential efficiency.
Although it requires further optimization
to achieve operational reliability, the successful
demonstration shows the potential of hydrogen
as a primary energy carrier for UAV and paves
the way for wider applications of hydrogen-powered
UAVs and small aircraft.
HYDRO-BUNNY: THE NEXT LEVEL
Building on the success of H2 FINITY, project HY-
DRO-BUNNY is advancing hydrogen technology
for UAVs. HYDRO-BUNNY is being carried out
jointly by TECCON, mb+Partner, ZAL and the IF-
PT at Hamburg University of Technology (TUHH).
The project is developing an autonomous refueling
system that supplies UAVs with hydrogen
and requires no human intervention. The combination
of a self-sufficient energy supply and an
HYDROGEN TAKES OFF – SUSTAINABLY INTO THE FUTURE
HIGH-PERFORMANCE, SCALABLE
HYDROGEN POWER TRAINS ARE
NECESSARY FOR LOW-CARBON
PROPULSION OF AIRCRAFT.
innovative refueling process ensures continuous
operational readiness even in remote areas,
significantly improving flight duration, efficiency
and economic viability. In addition to gaseous
hydrogen, the use of liquid hydrogen is also being
investigated in order to further increase the
energy density and enable even longer flight
times.
PRACTICAL APPLICATIONS
HYDRO-BUNNY opens up new possibilities for
the use of UAVs in critical and demanding missions.
For example, drones could control large
hilly areas of forest thanks to self-sufficient energy
supply and autonomous hydrogen refueling.
The integration of liquid hydrogen technology
significantly increases the range and enables
long-duration missions with minimal maintenance
effort.
Mid-term milestone meeting at ZAL on April 10, 2024.
63
ACKNOWLEDGEMENTS
H2 FINITY and HYDRO-BUNNY are part of the initiative
GATE (Green Aviation Technologies). The
project is supported by funds of the city of Hamburg
and administered by IFB Hamburg. First flight at Rotenburg airfield on November 8, 2024.
Self-sufficient
H 2 supply unit
H 2 hose
Sensor solutions
for coupling / refueling
process
H 2 interface
Drone – Supply unit
Drone lock
Refueling process
Modified H 2 drone
Starting / landing platform
System overview of the Hydro-
Bunny hydrogen refueling process.
Automatic
refueling system
REALISE system
PRODOSE
The technician (in yellow jacket) receives guidance from a remote expert, who is seamlessly integrated into the local scene via smartphone or tablet.
64
VISIOPORTATION –
TELEPORTATION
IS NOW!
CONTACT
Rudi Sordes
rudi.sordes@prodose.de
PRODOSE has been a new player at the ZAL
TechCenter since 2024. Specializing in research
and development, PRODOSE is a Tier 1
subcontractor for Airbus and holds a portfolio
of nearly 200 patents worldwide. PRODOSE
revolutionizes remote assistance with VISIO-
PORTATION.
PRODOSE has been providing aircraft maintenance
services to airlines and aerospace manufacturers
since 1999. It operates globally, which
led its R&D teams to identify a strategic need:
bridging the gap between field experts and end
users in maintenance and production. This is
how VISIOPORTATION was born.
AN INNOVATION COMPLEMENTARY TO
AUGMENTED REALITY
VISIOPORTATION is a groundbreaking advancement
that enhances remote collaboration by
enabling the real-time fusion of two or more
real environments into a single shared experience.
This concept, called “real reality” (registered
PRODOSE trademark), , is designed to
complement existing technologies like augmented
reality by offering a different approach
to immersive interaction.
This technology allows for the virtual teleportation
of any expert or remote advisor into the
physical environment of a user requiring support.
VISIOPORTATION – TELEPORTATION IS NOW!
“We were genuinely surprised to see a
person ‘teleported’ into a real scene
from several kilometers away. It was
mind-blowing!”
Dr. Morou Boukari, project manager at VISIOPORTATION
While augmented and virtual reality focus on
creating or overlaying digital elements onto a
scene, VISIOPORTATION provides an instantly
operational solution for multiple equipped
users, requiring no time-consuming or costly 3D
modeling.
“At the beginning of the project, when we created
the first prototype, we knew the potential of
the technology we were developing and patenting.
However, we were genuinely surprised to
see a person ‘teleported’ into a real scene from
several kilometers away. It was mind-blowing!” –
says Dr. Morou Boukari, project manager at VI-
SIOPORTATION.
DEPLOYMENT AND INITIAL APPLICATIONS
Currently, VISIOPORTATION is in its testing phase
in the aircraft production and military sectors. In
aircraft production, assembly technicians must
manage a wide variety of equipment, making process
standardization more complex. VISIOPORTA-
TION enables them to receive instant assistance
from an expert, as if they were physically present.
A FAR-REACHING IMPACT
BEYOND AEROSPACE
While aerospace is the first field of experimentation,
VISIOPORTATION was designed as a universal
solution with numerous potential applications:
• Military and security operations: intervention
teams can be guided in real time by a command
center, with images transmitted via
drones, creating direct immersion for decisionmaking.
These applications have already been
successfully tested.
• Medical sector: imagine a doctor or nurse
virtually teleported to a patient’s bedside on
the other side of the world to provide instant
guidance.
65
• Fashion and personalized consulting: a top
designer could advise a client 5,000 km away,
appearing as if physically present to offer tailored
recommendations.
• Immersive customer experience: a product
specialist could assist a remote buyer, providing
real-time advice in an interactive virtual
showroom.
Example of a VISIOPORTATION advisor’s workstation.
With its innovative approach, VISIOPORTATION
is more than just a technological breakthrough –
it is redefining the way humans interact remotely.
The future of immersive collaboration starts
today.
SIEMENS
VIRTUAL
CERTIFI CATION
USING THE
DIGITAL THREAD
• Lack of automated traceability: rough
traceability is manually achieved by reports
with written-down references, complicating
certification audits and hindering automation.
66
To mitigate these inefficiencies, a CAD-CAE integrated
framework was proposed, leveraging
Simcenter 3D and Teamcenter Simulation to enforce
data continuity, automation and configuration
management.
Transforming engineering processes for more cost-effective certification
is crucial for technology leadership.
See background
information on
integrated design
analysis.
Aircraft structural engineering evolves
across three primary phases: conceptual,
preliminary and detailed design. Each stage
involves an increasing number of design
variables, shifting the focus from optimization
to compliance validation. Traditional
workflows suffer from inefficiencies due to:
• Siloed design and analysis work: mostly
manual data exchange, limited transparency
between different domains.
• Cumbersome design updates: with unclear
data flow, changes require high effort and time
and increase the risk of errors due to inconsistent
data.
DIGITAL THREAD IMPLEMENTATION:
A STRUCTURAL WORKFLOW
FOR DRONE DESIGN
The methodology is demonstrated on a remotely
piloted surveillance aircraft, subject to 1445
critical load cases derived from aerodynamic
and inertial considerations. The workflow comprises:
1. Load Case Derivation: static aeroelastic
analysis determines critical flight conditions,
leveraging NASA-derived maneuver definitions.
2. FEA model development: associative geometry
linking ensures direct connectivity between
CAD and global (GFEM) and detailed
(DFEM) finite element models.
3. Margin of Safety (MoS) calculation: integrated
stress assessment eliminates manual
data handling, providing real-time structural
compliance metrics.
VIRTUAL CERTIFI CATION USING THE DIGITAL THREAD
“How can we avoid that increasing certification
cost is hindering innovative future aircraft
developments? The digital thread will be a
key-enabler for technology leadership.”
Dr. Christoph Starke, Siemens Industry Software GmbH
4. Optimization via design space exploration
(DSE): automated parameter studies refine
structural thicknesses and mass distributions
while maintaining required MoS.
EFFICIENCY GAINS AND CERTIFICATION
READINESS
This fully digitalized process yields two substantial
improvements:
• Accelerated design iterations, enabling faster
trade-off studies and thereby optimized structural
weight, balancing material efficiency with
safety margins.
• Automated compliance documentation, ensuring
long-term certification traceability at lower cost
compared to manual tracing on report basis.
CONCLUSION
By integrating geometry, simulation and certification
workflows within a continuous digital
thread, this approach demonstrates significant
reductions in engineering lead times and regulatory
overhead. The proposed methodology
supports a paradigm shift towards simulationdriven
certification, paving the way for more
efficient aircraft development and streamlined
regulatory approval processes.
CONTACT
Dr. Christoph Starke
christoph.starke@siemens.com
67
Read the full
research paper here.
Visualization of the fictitious surveillance drone. The drone design was performed by
Siemens as a proof of concept for a certification-directed design approach using the
digital thread, ensuring automated traceability of all data flow and design versions.
IMPULSES & OUTLOOK
ZAL EXPERT
COMMUNITY
68
Since the launch of ZAL TechCenter, the Innovation
Services division has become a
trusted partner for support in research and
technology projects. Initially, its primary focus
was addressing the immediate needs of
one key partner by providing testing, hardware
support, services and collaborative
funding projects. Furthermore, funded research
projects have been carried out in collaboration
with SMEs, universities and research
institutions. Through joint industry
and funding projects, ZAL Innovation Services
supports the networking of experts
and partners as well as the definition and
utilization of the technical infrastructure at
ZAL TechCenter.
Players involved
In its current phase, the Expert Communities
consist of representatives from ZAL’s
supervisory board (Airbus, LHT, DLR, ZAL
Association, universities, BWI Hamburg),
who nominate technically skilled individuals
with decision-making authority based
on the topics at hand. For further development,
the participant group is expected to
expand to include experts from additional
partners within the Hamburg metropolitan
region. In the long term, participation
by qualified professionals from related
fields (e.g., wind energy, automotive industry,
shipping) is also envisioned to explore
potential synergies.
To further enhance the efficiency and impact
of these activities, the division is now refining
its focus areas with so-called Expert Communities.
These communities identify core competencies
and align them with the evolving needs
of ZAL partners. The Expert Communities serve
as cross-partner exchange and communication
platforms, promoting trust, open dialogue and
constructive technical collaboration. This approach
increases transparency and mutual understanding
of each partner’s activities, allowing
for their further development based on
real-world requirements.
A key focus of this initiative is aligning ZAL Innovation
Services’ topics and offerings with the
specific interests of the aviation community.
This includes services, research demonstrators
and research infrastructure tailored to industry
requirements. The shared goals reflect both
the shareholders’ immediate needs and Hamburg’s
strategic innovation priorities. The communities
also evaluate longterm trends, identifying
required research hardware, skill sets
and potential areas for growth and development.
The topics explored within the Expert Communities
are guided by five key criteria:
1. Aviation-relevant megatrends
2. The global aviation ecosystem
3. Strategic priorities for Hamburg
4. ZAL’s core business activities
5. Interest from at least two ZAL shareholders
ZAL EXPERT COMMUNITY
Results & success
An exemplary success of the
Expert Communities is the collaborative
development that has led
to the Green Aviation Technology
Roadmap, see p. 32–33.
These criteria directly shape the Innovation
Services’ focus areas, enabling meaningful and
future-proof collaboration with partners at ZAL
TechCenter.
At the request of the Expert Community participants,
the next phase will tackle high-potential
topics, including: developing an open, neutral
cabin reference architecture at ZAL, bridging
the industrialization gap between TRL6 and
TRL7 and supporting operations through
shared infrastructure. These ambitious initiatives
present unique challenges for all partners.
However, a collaborative approach will
pave the way for effective and sustainable
solutions, strengthening innovation within the
aviation industry and beyond.
Way of working
The Expert Communities are organized and
facilitated by ZAL GmbH. Designed as workshop-style
events, these gatherings take
place in person at ZAL TechCenter. This format
has proven effective in fostering
trust-building discussions, where more detailed
background information can be
shared – essential for deeper mutual understanding.
Currently, workshops are held
twice a year, during which ongoing topics
are presented and discussed and potential
new topics identified. In addition, supplementary
workshops are being planned to
develop further collaborative activities.
69
ZAL in Hamburg is a hub
for Networking, Collaboration,
and Innovation for the
Future of Aviation.
ZAL Vision
You have questions or suggestions –
or you want to participate in the Expert
Communities? We look forward to
hearing from you – feel free to reach out!
FEV
FEV DETECTS
HIGH-VOLTAGE
DISCHARGE IN
AEROSPACE
70
CONTACT
Roman Schilke
schilke@fev.com
FEV, a leading global engineering service
provider and innovation leader for aerospace,
sustainable mobility, software and
energy solutions, has developed PD-HVX
(“Partial Discharge – High Voltage X”), the
world’s first solution for the early detection
and prevention of partial discharge in
high-voltage electric propulsion systems.
PD-HVX is now also being adapted by FEV to
the aerospace sector.
Partial discharge (PD) describes a local electrical
sparkover that can occur at high voltages above
several hundred volts. This has the potential to
cause damage to the insulation in modern electrical
motors, which in the worst-case scenario
may result in a total failure of the propulsion
system. FEV’s PD-HVX uses well-established
measuring systems with specialized sensors,
which are used for high-quality measurement in
electrical propulsion systems in aerospace like
in electric/hybrid turboprops. With this, FEV
helps its customers to identify partial discharge
during the development phase and take the
necessary actions to prevent damage due to
premature propulsion failures and additional
costs during development.
In aircrafts with electrical propulsion this risk of
partial discharge in electrical motor windings is
even higher due to the altitude and consequently
less air pressure compared to propulsion
units in ground vehicles. PD is caused by extremely
small defects or inhomogeneities in the
insulation material or contamination of surfaces.
If remained unnoticed within an electrical
propulsion system and occurring repeatedly,
this leads to gradual damage of the insulation
and to a premature stop of the propulsion.
PD-HVX uses electromagnetic frequency analysis,
one of the most precise and reliable measurement
methods in the field of electrical propulsion
systems with electrical motors and
motor control units like inverters. By this, the
electromagnetic fields around connections of
the motor and its motor control unit can be analyzed.
In a next step, the innovative system
then uses the measurement results to determine
whether partial discharges occur within
the electrical propulsion during operation.
PD has been known for a long time in the field of
electrical systems engineering and high-voltage
transmission networks, where corresponding
tests are common practice. In the aerospace
sector, the phenomenon is just gaining focus
with the increasing application of power electronics
like in airworthy electrical propulsion
systems, where either fuel cell power supply
FEV DETECTS HIGH-VOLTAGE DISCHARGE IN AEROSPACE
71
FEV’s PD-HVX allows high-quality measurement in electrical propulsion systems in aerospace.
and/or high voltage batteries are used as energy
sources for electrical propulsion systems.
Thanks to FEV’s many years of expertise in the
development of electrical propulsion systems
for aerospace, with PD-HVX the company can
now provide a dedicated solution for PD detection
on the spot.
This solution consists of a holistic service package
for aircraft manufacturers and tier-1 suppliers.
The test equipment, which is optimized for
electrical propulsion operation, filters out propulsion-related
interference signals and there-
fore enables significantly better measurement
results for PD. The customer subsequently receives
the data obtained in the tests for evaluation
and further interpretation.
FEV has a long track record in power, propulsion
and control electronics as well as various areas
of sensor technology. On request, the customer
can also make use of this expertise in data analysis
and system optimization.
Find out more
about FEV.
ZAL GMBH
72
Fynn Schröder working on the H 2 -Carrier in the ZAL H 2 drone lab.
H 2 DRONES:
FROM PROTOTYPE TO
COMMERCIAL REALITY
CONTACT
Fynn Schröder
fynn.schroeder@zal.aero
There are high hopes for drones playing a
major role in civilian applications, offering
significant benefits to industries and society
alike. For example, inspecting kilometers
of power lines could be done from the
air, or urgent blood supplies could be delivered
past traffic jams – without the need for
costly helicopter operations. However, the
limited range and flight time of commercially
available drones remain a barrier – most
battery-powered models need to land after
just around 30 minutes of flight time.
Hydrogen-powered drones break through these
limitations. Using compressed gaseous hydrogen
(GH 2 ), these drones can achieve flight times
of up to four hours. Yet, until now, they’ve primarily
been the domain of hydrogen specialists,
such as members of the ZAL Fuel Cell team, who
have designed and operated these systems for
H 2 DRONES: FROM PROTOTYPE TO COMMERCIAL REALITY
More info about
the collaboration.
research purposes. For these visionary applications
(see infobox) to become reality, the technology
needs to be more accessible.
To address this challenge, ZAL’s Hydrogen Drone
team has joined forces with Premium-Modellbau
to develop a hydrogen-powered octocopter
(H 2 -Carrier) that can be operated by non-fuel-cell
experts in everyday operations. ZAL is responsible
for integrating a fuel cell and hydrogen storage
system, followed by rigorous ground and
flight testing to ensure the drone’s reliability and
performance. Premium-Modellbau, the largest
UAV components reseller in the DACH region,
specializes in designing and manufacturing custom
drones for industrial and research applications.
As a leading provider of multicopter and
drone components, they not only develop professional
UAV solutions but also ensure reliable
spare parts support – making hydrogen drones a
viable solution for everyday use.
Long range, low cost:
the benefits of
hydrogen drones
Hydrogen drones are more than just an innovation
for extended flight times. Their long-range
capability makes them a cost-effective and lowemission
alternative to helicopters, enabling entirely
new applications in remote and challenging
environments that were previously impractical
with conventional drones.
INSPECTIONS
Offshore and onshore
inspections: powerlines,
pipelines and
railways
73
H 2 bottle
quick refill
Foldable arm
for easy transport
SURVEILLANCE
Search and rescue
missions, fire fighting,
situational assessment
Up to 4 h
flighttime
LOGISTICS
Up to 5 kg
payload
Time-critical logistics:
medical supplies,
emergency support
ZAL’s H 2 -Carrier drone: a compact yet powerful system designed
for easy deployment in a wide range of scenarios.
THELSYS
System of systems: a methodology
for assessing the
impact and benefits of an
innovation.
74
WHAT WEIGHT IS YOUR
INNOVATION?
SYSTEM OF SYSTEMS
System of Systems is an innovative approach to
creating aviation products and services that are
designed in a truly holistic manner. The underlying
idea is twofold: (1) to perform better in the
face of the conflicting priorities of climate impact,
sustainability, safety and economic success;
and (2) to become more resilient to the impacts
of disruptive markets and supply chains,
digitalization, and regulatory and economic policy
interventions.
THE PROJECT
The EU project COLOSSUS takes the methodology
of System of Systems Engineering (SoSE) and
reverses it: instead of the top-down approach of
developing a network of various interacting systems,
it takes the bottom-up perspective of optimizing
the integration of a new system into an
existing network. The approach targets the very
early stages of innovation and product development
and then accompanies the design process
in the form of periodic “reality checks.”
Read more about
COLOSSUS on LinkedIn.
THE MOTIVATION
In today’s complex and dynamic market environment,
our perspective in research and product
development is often too narrow. In the early
stages, the question now shifts from “How do I
solve this problem?” to “What problem should I
solve?” Only when priorities, trends, interactions
and interdependencies as well as other external
influences are fully considered and understood
can a robust solution be found that will succeed
in tomorrow’s reality.
THE OBJECTIVES
COLOSSUS aims to develop a research and innovation
(R&I) platform for the design and optimization
of new technologies, products and services
that allows for a new level of impact
assessment and interaction with the “real world.”
It is a logical continuation of AGILE, a European
research project that received the prestigious
ICAS Award for Innovation in Aeronautics from
the International Council of the Aeronautical Sciences
in 2018, and its successor AGILE 4.0.
WHAT WEIGHT IS YOUR INNOVATION?
Optimization of system networks through the combination
of technologies or products
Optimization of product or technology through integration
into system networks
direction of view
direction of view
A matter of perspective: strategies for analyzing networks of interoperating systems (left) and products in their future environment (right).
75
THE CONTENT
The project explores two product development
principles: “technology push,” where innovation
seeks a marketable application, and “market
pull,” where existing or emerging demand seeks
a solution. Each principle is analyzed through a
use case: sustainable mobility (push) and a forest
fire scenario (pull). The challenge is to introduce
two new products, a hybrid seaplane and
an eVTOL commuter vehicle, in both scenarios
and to optimize the requirements and conceptual
design in a holistic “real world” environment.
Of course, the goal is not to come up with viable
products, but to sharpen the system-of-system
design process, its design tools, and the framework
in which they are embedded.
ACKNOWLEDGEMENTS
COLOSSUS has been funded by the European
Union under Grant Agreement No. 101097120.
The project involves 14 partners from seven
European countries. With ZAL tenant DLR Institute
of System Architectures in Aeronautics as
coordinator and ZAL Förderverein member
Thelsys as the second German partner, ZAL can
be considered as the pivot and hub of this European
initiative.
Find out more
about COLOSSUS.
CONTACT
Dr. Martin Spieck
martin.spieck@thelsys.de
THE VALUE
The potential benefits of the project are manifold:
from the COLOSSUS Academy to support
university education, to freely available design
tools, to the methodical development of research
and development processes in the aerospace
industry. Stay tuned for the project website
and the COLOSSUS LinkedIn channel for the
latest developments and results.
Simulation of a wildfire in Greece: eVTOLs and seaplanes in an indirect
attack strategy.
IMPULSES & OUTLOOK
All episodes of the Hamburg
Aviation Green Podcast can
be found here.
LISTEN.
AND BE
INSPIRED.
Tired of reading? Here are three exciting
podcast episodes for you – enjoy!
LISTEN ON
76
Hydrogen is gaining traction in
aviation. But can liquid hydrogen,
a cryogenic fuel, be refueled
efficiently at commercial
airports? The Hydrogen Aviation Lab in Hamburg
is tackling this question. Using a decommissioned
A320, this real-world test facility – funded during
the pandemic – explores key challenges for hydrogen
adoption. Hans Bernd Aringhoff, Head of Corporate
Innovation at Lufthansa Technik, shares insights
into the lab’s work, that of its partners (DLR,
ZAL, Hamburg Airport) and its vision for a hydrogenpowered
future.
EPISODE #7: HANS BERND ARINGHOFF
HYDROGEN
AVIATION LAB:
PUSHING FORWARD
H 2 ADOPTION IN
HAMBURG
HAMBURG AVIATION GREEN PODCAST
Hydrogen could revolutionize
aviation – but at what cost?
Dr. Lucas Sens from TU Hamburg
explains findings from a EU
study on hydrogen adoption. By
2050, 65 percent of EU flights
could use hydrogen, with tickets
costing just seven percent more. Sens discusses Airbus’
ZEROe project, carbon pricing and salt caverns
for hydrogen storage. This episode dives into the
economic and technological challenges shaping aviation’s
green future.
EPISODE #8: DR. LUCAS SENS
HYDROGEN
AVIATION:
THE CHANCES, THE
COSTS, THE FUTURE
EPISODE #9: DR. BJÖRN NAGEL
LONG-HAUL
SOLUTIONS AND
DIGITAL TOOLS
FOR GREEN
AVIATION
In the first episode of Season 2 of Hamburg
Aviation Green, Angus Baigent and Caroline
Oxley talk to Dr. Björn Nagel, Director of the
DLR Institute of System Architectures in Aeronautics.
Which technologies hold the greatest
potential for greener aviation? How can climate
impacts be reduced? And what role does
hydrogen play, especially on long-haul routes?
Nagel shares insights into pioneering DLR
projects like EXACT and ALICIA and explains
how Hamburg's research ecosystem is shaping
the future of sustainable aviation.
77
IMPULSES & OUTLOOK
THE POTENTIAL
OF PROTECHNICALE
ALUMNAE
78
proTechnicale represents excellence in
STEM promotion and has set standards in
training and preparing young women to join
technical professions for over a decade.
The program offers two formats:
proTechnicale School (since 2022) is a hybrid
program for schoolgirls from grade 10 onwards
to explore STEM courses and professions, build a
network and strengthen their personalities.
proTechnicale Classic (since 2011) is a gap
year, in which female high school graduates experience
STEM degrees and professions handson,
acquire expertise, deepen social skills and
strengthen their personalities.
LISA STEINHAUSER
Project Manager for Quantum Technologies @hqic/ari
INGA MEYENBORG
Product Development Engineer @jetlite
What advice would you give to young women who are
thinking about taking part in proTechnicale?
Be courageous, be curious – take the chance of a year packed
full of new experiences, impressions and discoveries. It offers
you the opportunity to try out different subject areas, take on
challenges and find out what really excites you. You will learn a
lot – about technology, about the world and, last but not least,
about yourself. Become who you are!
With over 250 alumnae, proTechnicale has built
a strong community, whose members support
and inspire each other. Many graduates now
work as engineers, scientists or managers – key
players in designing and implementing innovative
solutions. In May 2024, over 80 alumnae
met at the first proTechnicale alumnae event at
ZAL TechCenter to exchange ideas and celebrate.
Topics ranged from pioneering technologies
and new work models to the role of women
in tech.
What is your profession today, and how did
proTechnicale prepare you for your path?
Today, I am a junior project manager at hqic, the City of
Hamburg’s initiative for quantum technologies. My time at
proTechnicale showed me that Hamburg is not only a wonderful
city that I enjoy living in, but also a hub for innovation
– one of the reasons I returned. Moreover, the program
empowered me to pursuing bold challenges and embrace
its philosophy of having faith and aiming for the stars. This
mindset led me to pursue my current job with the mission
of unlocking quantum technologies’ potential to solve complex
problems and make the world a better place.
A unique atmosphere filled the building, reflecting
what truly defines the proTechnicale community
– not just professional qualifications, but
a mindset of openness, curiosity and the drive
to tackle social and technological challenges.
A STRONG COMMUNITY AND
A MEANINGFUL MISSION
These excerpts demonstrate the courage and
drive of proTechnicale graduates. Their professional
success and passion for technology in-
THE POTENTIAL OF PROTECHNICALE ALUMNAE
spire people far beyond the community – a community
that is actively shaping the future of tech.
Companies benefit from this dynamic, whether
through fresh innovation or collaboration with
women ready to change the world.
Over 80 proTechnicale alumnae gathered at ZAL TechCenter to exchange
ideas, celebrate together and experience inspiring keynotes in an innovative
space. In the front row, you can also see founder and shareholder of
SOPHIA.T gGmbH Manfred Kennel (fifth from the right) and and proTechnicale‘s
Managing Director Friederike Fechner (far right).
79
As Friederike Fechner, Managing Director of
SOPHIA.T gGmbH says: “Our proTechnicale mission
is to inspire and empower future leaders to
strive toward a more diverse, innovative and
promising world.”
AYLIN BAHRAMPOUR
Dual student @Lufthansa Industry Solution
What skills or insights did you gain during your time
with the proTechnicale School program?
I learned the programming language Python and also realized
how important it is to network with other people. I got to know
many different jobs and study programs such as aerospace,
mechanical engineering and mechatronics that I hadn’t really
come across beforehand and had the chance to meet many
successful women who inspired me a lot. I also learned that
computer science is not just about programming; that there is
a lot more you can do with it.
VALERIE DAU
Mechanical engineering student @RWTH Aachen University
What inspired you to apply for both proTechnicale
programs School and Classic?
I was already deeply interested in STEM through practical subjects
at school, such as the “Chemistry in everyday life” workshop.
My mother found proTechnicale and drew my attention
to it, as I didn’t yet know where my journey would take me. With
my internship at Lufthansa Technik and my Girls’ Days there
and in German air traffic control, I realized that I was particularly
interested in the field of aviation. I found the variety and
diversity of the proTechnicale School program highly inspiring,
which is why I also applied to proTechnicale Classic after my
Abitur – for more deeper insight.
CONTACT
Wiebke Pomplun
office@protechnicale.de
For more information
please visit
www.protechnicale.de
IMPRINT
ZAL CENTER OF APPLIED
AERONAUTICAL RESEARCH
Hein-Sass-Weg 22
21129 Hamburg, Germany
+49 40 248 595 0
info@zal.aero
zal.aero
linkedin.com/company/zaltechcenter
facebook.com/ZALTechCenter
80
EDITORIAL
Miriam-Joana Flügger, ZAL GmbH
Georg Wodarz, ZAL GmbH
CONCEPT & DESIGN
FORMBA GmbH
info@formba.de
formba.de
PRINT PRODUCTION
RESET ST. PAULI Druckerei GmbH
info@resetstpauli.de
resetstpauli.de
PHOTO CREDITS
Cover: Daniel Reinhardt; p. 2: Daniel Reinhardt; p. 6–7: icons by FORMBA GmbH (Merle Rosen); p. 9: Daniel Reinhardt, illustration by FORMBA GmbH (Ines
Thaller); p. 10–11: Daniel Reinhardt (2); p. 12–13: SFS (2); p. 14: Daniel Reinhardt; p. 16–17: VÆRIDION GmbH, FACC AG; p. 18–19: ZAL GmbH (Georg Wodarz),
Daniel Reinhardt (2); p. 20–21: Daniel Reinhardt (2); p. 22–23: Daniel Reinhardt (2); p. 24–25: Daniel Reinhardt, esploro (7); p. 26–27: Akkodis (2);
p. 28–29: Daniel Reinhardt (2); p. 30–31: Daniel Reinhardt (4), DLR (Philipp Czogalla); p. 32–33: Shutterstock (Gerckens- Photo-Hamburg), Daniel Reinhardt;
p. 34–35: Daniel Reinhardt (3); p. 37: Daniel Reinhardt, DLR Screenshot of Digital Hangar; p. 38–39: Daniel Reinhardt (2); p. 40–41: jetlite (3); p. 42–43:
FFT (2); p. 44–47: Lennart Dobravsky, illustrations by FORMBA GmbH (Merle Rosen); p. 48–49: Daniel Reinhardt, ZAL GmbH (Georg Wodarz, 3); p. 50–51:
BOCKFILM GmbH, Benjamin DEBUSSCHERE; p. 52–55: Fraunhofer IFAM (6); p. 56–57: Capgemini, Andreas Kötter; p. 58–59: Daniel Reinhardt, ZAL GmbH
(Georg Wodarz); p. 60–61: ZAL GmbH (Georg Wodarz, 4); p. 62–63: TECCON (3); p. 64–65: PRODOSE (2); p. 66–67: SIEMENS (2); p. 68–69: illustration by
FORMBA GmbH (Ines Thaller); p. 70–71: FEV; p. 72–73: Daniel Reinhardt, Unsplash (Jesse de Meilenaere, Michael Chacon), Sonja Brüggemann; p. 74–75:
Thelsys, AI-generated content using Canva (3), DLR, montage using Goolge Earth (Landsat/Copernicus image, © 2025 Airbus); p. 76–77: Lufthansa Technik,
Lucas Sens, DLR; p. 78–79: proTechnicale (Kristin Fock, 3), private (2)
THIS MAGAZINE WAS PRINTED IN A CLIMATE-NEUTRAL AND RESOURCE-SAVING WAY.
Tell us! Do you like the magazine?
And would you like your ZAL project to
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Future. Created in Hamburg.