FUTURED. ZAL Magazin 2023

Future. Created in Hamburg. 

FROM H 2 TO AI 

Check out current research pro jects 

at ZAL TechCenter. And discover 

promising approaches that will 

change aviation soon. 

T 

ZAL MAGAZINE 

2023 

u 

r 

WIFM? 

WHAT’S IN FOR ME? 

Find out about ZAL’s expansion: how the 

Open Hangar Space and the integration 

of a start-up ecosystem will affect collaboration 

at ZAL TechCenter. 

U 

e 

PAPER OR DIGITAL? 

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reading, listening, and watching! 

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FUTURED. 

ZAL MAGAZINE

Dr. Melanie Leonhard, Senator 

for Economics and Innovation in 

Hamburg, and Roland Gerhards, 

CEO at ZAL GmbH. 

2 

“We will only be able to 

implement complex topics 

such as emission-free 

mobility if we work together.” 

Dr. Melanie Leonhard

“WE MUST 

CONTINUE 

TO DRIVE 

INNOVATION” 

Since the beginning of the year, Dr. Melanie Leonhard 

has been the first female senator to hold the office of 

the Ministry of Economy and Innovation. In this role, 

Melanie Leonhard is also an active member of the ZAL 

shareholders’ meeting, which means she plays a key 

role in steering the future and agenda at ZAL. 

GERHARDS Ms. Leonhard, you have an affinity for maritime. 

As a historian with a doctorate, your work covered the history 

of the Rickmers entrepreneurs, a shipowning and shipbuilding 

family. What aviation issues will you be promoting? 

LEONHARD Aviation – like maritime – is a key industry in Hamburg. 

Both contribute significantly to the prosperity of our region. 

Our goal is therefore to continue to be attractive for 

companies and skilled workers. To achieve this, we must continue 

to drive innovation. ZAL plays a central role in this. I consider 

the expansions with ZAL II and ZAL III as well as the 

stronger integration of start-ups via the Sustainable Aero Lab 

to be extremely important. 

GERHARDS Politics, business, and science are pulling to gether 

in Hamburg. This is something that the international aviation 

community envies us for, as people keep telling me. But will 

that be sufficient? An innovative environment is of little use if 

people and know-how are lacking. 

how we can attract more women and young talents, for example. 

But we will also have to make our focus more international. 

GERHARDS A special challenge awaits us in the area of hydrogen. 

As a crucial element in the energy transition, all areas 

need to be staffed with infrastructure and specialist personnel. 

These range from production and storage to transport 

and application. 

LEONHARD Yes, and I am convinced that the establishment of 

the ITZ, an innovation and technology center for aviation and 

maritime focused on hydrogen and fuel cells, can accelerate 

both issues: the development of hardware and know-how in 

parallel. A very good move, I think, from which ZAL will also 

benefit. 

GERHARDS We have high hopes that the partial integration of 

ITZ Nord into ZAL will develop a boost for small and medium-sized 

enterprises and start-ups, so that previously interested 

players will dare to take the step in practice. We are also 

looking forward to the synergies that will result from the 

integration of maritime and aviation. 

LEONHARD I feel the same way, there is still a lot of potential 

in this. We will only be able to implement complex topics such 

as emission-free mobility if we work together. 

3 

LEONHARD I agree with you there. We need more skilled workers, 

well-trained people who want to work and live in Hamburg. 

As a city, we are therefore working on the further development 

of our skilled labor strategy. It is clear that we must continue to 

make efforts and that the solutions are complex. However, 

there are already strong initiatives such as Pro Technicale and 

the NAT Natural Sciences and Technology program which show 

GERHARDS Allow me to finish with the question: assuming 

you’re traveling to New York – by plane or ship? 

LEONHARD (laughs) On the way there by ship as the anticipation 

gradually increases during the time on the water. And on 

the way back by plane, it can be quick, because I also love being 

in Hamburg.

CONTENTS. 

AI & 

DIGITALIZATION 

AUTOMATION 

HYDROGEN & 

SUSTAINABILITY CABIN DRONES 

IMPULSES & 

OUTLOOK 

4

The FUTURED magazine is for reading, 

listening and watching! 

Article 

Audio 

Email 

Video 

Website 

06 IMPULSES & OUTLOOK Young Future – What Does Aviation Mean to You? 

08 AIRBUS CENTRAL R&T Disruptive Technologies for the Future Aircraft 

12 LUFTHANSA TECHNIK A New Life for an Old A320 Aircraft 

14 DIEHL AVIATION Smart Galley Takes Off 

16 CAPGEMINI Supply Chain Transparency and Protection of Company Secrets 

18 ZAL GMBH Would You Fly AI? How to Certificate AI Systems 

20 IMPULSES & OUTLOOK ZAL TechCenter Expansion 

24 IMPULSES & OUTLOOK ZAL Start-up Ecosystem 

26 DLR SL DLR SL Research at ZAL 

28 DLR MO Listening Closely, The Human in the Loop 

28 DLR TT DLR at ZAL Fuel Cell Lab 

30 DASSAULT SYSTÈMES Engineering Collaboration Network 

32 AIRBUS Intelligent Modular Robotics and Production Design 

33 AIRBUS Mixed Reality Demonstrator 

34 ZAL GMBH What Makes an Aircraft Cabin Smart? 

36 AES Creating Solutions with Tomorrow’s Technology 

38 IMPULSES & OUTLOOK Hamburg Aviation Green Podcast 

40 ZAL GMBH The Future of Aviation is About Acoustics, Too! 

42 FRAUNHOFER IFAM Smart Aircraft Assembly 

46 HAW Research for Sustainable Aircraft 

48 IDS In the Sky, on Land, and at Sea 

50 IMPULSES & OUTLOOK ITZ – Enabling Hydrogen for Aviation & Maritime 

52 IMPULSES & OUTLOOK Fueling Hydrogen 

54 AIRBUS ZEROe “We Set Ourselves Up for Great Challenge” 

56 AIRBUS SCALE Pioneering a Circular Carbon Economy with Direct Air Capture 

58 ZAL GMBH Liquidrone & Wingcopter 

60 LUFTHANSA TECHNIK Hydrogen Aviation Lab 

62 DLR MO, SL, TT Hydrogen Aviation Lab 

64 TECCON Environmentally Friendly into the Future 

66 IMPULSES & OUTLOOK proTechnicale – We Empower Future Tech Talents 

68 SIEMENS “We are Ready to Shape the Future” 

70 IMPULSES & OUTLOOK ZAL e. V. – Executive Board Now with Four Chairmen 

72 IMPULSES & OUTLOOK ZAL Innovation Day – Making Change Happen 

76 Imprint 

5

IMPULSES & OUTLOOK 

ZAL TechCenter is a regular host for 

school groups, students, and other future 

young professionals. We asked: 

WHAT DOES 

AVIATION MEAN 

TO YOU? 

6 

Flying, even with rockets, 

allows people to explore 

the world. 

PER, 15 

Why don’t we use solar 

energy when flying above 

the clouds? 

ENRICO, 12 

I’d rather 

not fly and 

protect the 

animals and 

nature. 

IDA, 8

YOUNG FUTURE – WHAT DOES AVIATION MEAN TO YOU? 

Aviation means fast 

mobility but also heavy 

environmental impact. 

Research is important to 

change that. 

MATILDA, 16 

Young visitors come to ZAL Tech- 

Center as part of various initiatives: 

Mint/NAT, Girls’ & Boys’ Days, 

class trips, proTechnicale, Hamburg 

Avia tion Young Professionals, 

DroneMasters Academy, New Flying 

Competition, and others. 

Register now for 

ZAL’s annual Girls’ 

and Boys’ Day. 

7 

Aviation means: future, globalization, 

access to new 

countries and people, technology 

and innovation, hydrogen 

(hopefully soon). In addition, 

it takes up a large share of 

the economy. It is impos sible 

to think of our world today 

without flying. 

LUISA, 16 

You’ll discover that the answers and statements 

are already influencing what we 

do at ZAL today. Just browse through the 

next pages to see what we mean.

AIRBUS 

8 

Airbus CRT team in Hamburg. 

DISRUPTIVE TECHNO 

LOGIES FOR THE 

FUTURE AIRCRAFT 

Airbus Central R&T is Airbus Group’s crossdivisional 

function for the development of 

“upstream” technologies in support of Airbus’ 

technology strategy and consists of scientists 

and experts in five areas (materials, 

communications, artificial intelligence, electrification, 

and virtual product development). 

Its approximately 150 researchers 

are spread across Europe, with research labs 

in France, the UK, and Germany. 

At ZAL in Hamburg, a team of 12 to 15 scientists 

and experts supported by interns and students 

work on topics related to communication, 

electrification, and virtual product engineering. 

Developments can be prototyped and investigated 

in the three laboratories, the Fuel Cell Lab, 

the Virtual Reality & Human Centered Technologies 

Lab and the Electronics Lab. 

FUEL CELL RESEARCH 

The main subject of the electrification group’s 

current research is to work on the development 

of novel high temperature solid oxide fuel cell 

(SOFC) concepts. The technology offers a high 

potential to increase the electrical efficiency of 

newly developed aircraft propulsion systems, especially 

when coupled with a gas turbine, but

DISRUPTIVE TECHNOLOGIES FOR THE FUTURE AIRCRAFT 

even when implemented just as an APU system 

in any airborne vehicle. Additionally, the SOFC 

offers an increased flexibility for the supplied fuel, 

because it relies not only on pure hydrogen, 

but can also cope with lighter hydrocarbon-based 

fuels or maybe even SAF. 

Originally developed for stationary power applications, 

the SOFC’s technical readiness level, especially 

for large-scale mobile applications, i. e. 

aircraft, is low compared to the state-of-the-art 

fuel cell technology (PEMFC, baseline for the ZeroE 

program). The basic research is consequently 

focused on decreasing the fuel cell weight 

while maintaining or even increasing its power 

output. With the help of advanced numerical 

methods and additive manufacturing and current 

collection technologies, a new cell design is 

under development and experimentally tested 

(single cell test bench in the picture), which will 

be the core for a new type of high temperature 

(SOFC) fuel cell concept. 

COMMUNICATION AND SENSING 

TECHNOLOGIES 

The communication and sensing group identifies 

and researches novel technologies that impact 

the architecture and operation of future aircraft. 

The research activities involve identification of 

use cases, conceptual design studies including 

theoretical and numerical assessments as well as 

the development of technology demonstrators. 

For example, the evaluation from 5G to 6G mobile 

radio communications will support connecting 

aerial vehicles to terrestrial and non-terrestrial 

networks offering new solutions for the 

passenger connectivity and aeronautical radio 

9 

Airbus XRE Fuel Cell Testbed.

AIRBUS 

10 

Find out more 

about Acubed. 

navigation, communication, and surveillance services. 

One of our tasks, in that regard, is to assess 

and contribute to these developments in 

cooperation with Airbus’ internal and external 

partners. 

Also, we are currently supporting Zero Emission 

efforts of Airbus by performing research on novel 

sensing solutions for liquid hydrogen propulsion 

systems. The figure below shows a demonstrator 

currently developed by the group to test 

new fill level gauging methods for aeronautical 

liquid hydrogen tanks. 

METHODS FOR AIRCRAFT AND INDUS TRIAL 

SYSTEM DESIGN 

At the Virtual Product Engineering group we develop 

new disruptive system engineering methods 

that enable us to perform multi-disciplinary 

analysis and optimization of novel aircraft configurations 

and their logistic and manufacturing 

systems. This enables several approaches: We 

can assess the resilience in an industrial system, 

simulate approaches to link industrial system human 

factors with MBSE models and by that enable 

the assessment of organizational resilience. 

Furthermore it enables us to use new approaches 

and algorithms making semantic checking to 

exploit the link between industrial system and 

product possible. We can also use generative design 

approaches to create and optimize architectures 

in MBSE models. The following IT approaches 

allow us to launch and explore large co-design 

architecture trades on the fly. 

PARTNERING WITH SILICON VALLEY 

Our products at Airbus bring people closer together, 

helping them unite and progress. True 

to this spirit, we have now also estab lished a 

strong collaboration with our Airbus innovation 

center in Silicon Valley – Acubed. Our dual student 

Karl Henning has been seconded into Silicon 

Valley to jointly develop a software prototype 

for industrial system analysis, combining 

Acubed expertise on the analysis of existing 

Airbus XR fill level gauging demonstration tank.

DISRUPTIVE TECHNOLOGIES FOR THE FUTURE AIRCRAFT 

In this picture our dual student Yarik Lasse Möller is 

demonstrating the Airbus XRV flight simulator testbed. 

11 

CENTRAL R&T WORKS ON UPSTREAM 

TECHNOLOGIES THAT OFFER AN 

OPPORTUNITY FOR ANY AIRBUS 

CHALLENGE AND REDUCES THE RISK 

ON PROMISING TECHNOLOGIES. 

Karl Henning at Acubed in Sunnyvale, USA. 

industrial systems with Central R&Ts DISM platform 

for multidis ciplinary analysis of aircraft and 

industrial systems. 

HUMAN-MACHINE COLLABORATION 

For the collaboration of humans with digital 

co-workers, for example in the assembly of aircraft 

together with workers and robots, the Human 

Centered Technology team is developing 

novel cognitive models. They enable the implementation 

of more intuitive and human-like 

behavior in digital assistants and robots. Our 

team consists of psychologists, computer scientists, 

and engineers and works closely with scientific 

institutes in neuropsychology and cognitive 

sciences. In our laboratory, we conducted 

ex periments with a flight simulator last year to 

derive the mental stress of pilots from physiological 

measurement data. This is an important 

prerequisite for predicting pilot behavior and, if 

necessary, offering support through digital assistants. 

CONTACT 

Arnd Schirrmann 

arnd.schirrmann@airbus.com

LUFTHANSA TECHNIK 

A NEW LIFE 

FOR AN OLD A320 

AIRCRAFT 

12 

Arrival of a former Lufthansa Group A320 fuselage section at ZAL TechCenter. 

It is a long, fascinating, but also challeng ing 

way for an old aircraft to become a research 

test facility. A significant mile stone 

was passed when the low loader truck – 

carrying a 20-meter segment of a retired 

A320 aircraft from the Lufthansa Group – 

reached ZAL Tech Center in the early morning 

hours. 

The night before, the convoy had started at the 

Lufthansa Technik base at the Hamburg airport 

– passing some popular sights of Hamburg 

downtown like the Kennedy Bridge and the At- 

lantic Hotel – before crossing the river Elbe – 

and finally reaching its new “home” – the ZAL. 

THE AEROGRAFT PROJECT 

This aircraft section is building the major part of 

a new test facility (mock-up) that is currently under 

construction. It will be used in the framework 

of an EU-funded research project called AERO- 

GrAFT. The project consortium is composed of 

Lufthansa Technik (lead), Christian-Albrecht University 

of Kiel, TU Dresden, and the companies 

Sixonia Tech GmbH, Phi-Stone AG, and Naturality. 

As part of the Graph ene Flagship initiative

A NEW LIFE FOR AN OLD A320 AIRCRAFT 

Find further 

informations on the 

AEROGrAFT website. 

ALMOST TWINS 

There were once two A320s that left the Airbus factory one immediately 

after the other. Both sister aircrafts entered service with the Lufthansa 

Group. The former D-AIQE flew for Germanwings, the D-AIQF for Lufthansa. 

And even today, the two sisters do not part ways. Thus, both aircrafts are 

changing their purpose to enter the service of applied aeronautical research. 

The D-AIQE is currently being converted into a cabin model at ZAL, 

while the D-AIQF forms the basis for the Hydrogen Aviation Lab. 

(funded by the European Commission), the 

AEROGrAFT project is about developing an innovative 

aircraft cabin air filtration system based 

on graphene pro viding enhanced filter performance 

– effectively capturing volatile organic 

compounds as well as particulate matter, dust, 

and bacteria. 

Start at the Lufthansa Technik base. 

13 

AEROGRAPHENE MATERIAL 

The filter material – called aerographene – is 

made by coating a removable porous ceramic 

template with graphene resulting in a struc ture 

composed of hollow graphene nanotubes. Besides 

this sophisticated material development, 

this project also utilizes the unique electrical 

characteristics of this material in order to establish 

smart functions like auto mated pollution detection 

and filter self-clean ing. The final research 

goal is the development of a smart and sustainable 

air filtration system for aircraft cabins. The 

new A320-based test stand will provide the ability 

for system performance and certification 

tests in a real aircraft system environment and 

allows maximum flexibility of multiple test scenarios 

in a realistic system context. 

FUTURE VISION FOR THE A320 MOCK-UP 

In a second step, the mock-up itself will be further 

developed by Lufthansa Technik to stepwise 

grow into a sustainable test and development 

platform for future research activities. Research 

A SEM picture of aerographene – hollow graphene nanotubes. 

topics such as wireless data communication, satellite 

connectivity solutions, digital cabin twins, 

or resource-efficient cabin components will be 

located here, enabling the way for new technological 

insights and innovative future products 

made by Lufthansa Technik. 

CONTACT 

Philip Herberger 

philip.herberger@lht.dlh.de

DIEHL AVIATION 

SMART GALLEY 

TAKES OFF 

14 

Florian Zager-Rode and Christian Hornemann discussing a system concept for the future galley. 

CONTACT 

Dr. Jörg Fuchte 

joerg.fuchte@diehl.com 

Diehl Aviation has been a part of the ZAL 

TechCenter since day one. The people working 

here coming from different departments 

of the Product Innovation and Digitalization 

division, representing different product 

groups and functions. Diehl further operates 

a laboratory for small test campaigns and 

demonstrators, while large-scale tests are 

conducted at the specialized sites of Diehl. 

The key mission of the ZAL team is to create innovative 

products and services for aircraft cabins, 

combining Diehl’s capabilities in production 

of light-weight structures, aircraft system, and 

cabin electronics. Integrating these technologies 

and bringing them to the market at accept- 

able costs is the daily challenge for Diehl’s ZAL 

team. To this end, the team works in close cooperation 

with other Diehl sites in Laupheim, 

Frankfurt, Dresden, and Munich. Products include 

the aircraft lavatory and galley, which are 

produced in Hamburg. 

A current project is a future galley incorporating 

all technological advances, enabling better service 

and lower emissions. The so- called eSmart- 

Galley enables airlines to collect, process, and 

transmit data for predictive health management 

and other data-driven services. Remote maintenance 

functions enable specialists from the 

ground to solve galley issues in the air with minimal 

impact on cabin crew operations.

SMART GALLEY TAKES OFF 

“The EcoDemonstrator campaign has demonstrated 

our ability to be agile and advance R&T 

results quickly to a flying prototype. 

The team at ZAL performed well, both as design 

lead of the campaign and as integrator for 

the other involved Diehl locations Frankfurt, 

Gilching, and Laupheim.” 

Carsten Laufs, Head of Product Innovation and Digitalization 

15 

Innovative insulation, flow-optimized ducting, 

3D-printed air guides and a modern power management 

with solid-state-power- control, door as 

well as latch detection make the eSmartGalley 

energy efficient, lightweight, and quiet. 

In order to advance these technologies, Diehl 

has included the EcoDemonstrator flight trials in 

Boeing. The ZAL team has designed a galley that 

took to the air on board a B777. Designed at 

ZAL, the monument was built at the Diehl Aviation 

Hamburg site in close proximity to ZAL. Systems 

were contributed by Diehl Aerospace 

(power management) and the colleagues from 

Gilching (cooling unit) and Laupheim (ducting). 

The monument was then shipped to Seattle and 

installed in the aircraft. 

Testing the Smart Lock Door. 

The eSmartGalley is a perfect example for applied 

research and technology activities. Although 

not resulting in an actual product, several 

elements are used in customer projects and 

the experiences in the flight campaign have 

helped these technologies achieve the required 

maturity. 

EcoDemonstrator aircraft landing in Frankfurt with 

Diehl eSmartGalley inside.

CAPGEMINI 

SUPPLY CHAIN 

TRANSPARENCY AND 

PROTECTION OF 

COMPANY SECRETS 

16 

If a product is to be optimized regarding its 

footprint, then a so-called LCA (life cycle assessment) 

is usually conducted first. Here, 

information about the materials used, raw 

materials, processes, energy required, 

transport routes, packaging, etc. is collected 

and evaluated. The ecological environmental 

impact of a product can thereby be 

obtained. This process alone requires an extensive 

collection of data. 

PROBLEM DESCRIPTION 

The project with a major customer from the production 

of industrial vehicles also proved that a 

holistic and efficient collection of the necessary 

data with a subsequent life cycle assessment 

can only succeed by automating the data flow. 

For this, there needs to be a possibility in the 

supply chain to not only collect one’s own data, 

but also the data of partners and suppliers 

along the value chain. Because everyone in the 

supply chain contributes signi ficantly to the ecological 

footprint. 

OUR SOLUTION 

For this purpose, Capgemini Engineering has designed 

a decentralized platform (CDX) that 

makes it possible to collect and evaluate any kind 

of product information from the entire supply 

chain. The prerequisite is that the participants in 

the supply chain are registered on this platform 

and enter their batches, components and complete 

products there. This takes place fully automatically 

and creates the bridge between the 

digital and the physical world. Now the manufacturer 

can be contacted and further information

SUPPLY CHAIN TRANSPARENCY AND PROTECTION OF COMPANY SECRETS 

BECAUSE EVERYONE IN THE SUPPLY 

CHAIN CONTRIBUTES SIGNIFICANTLY 

TO THE ECOLOGICAL FOOTPRINT. 

More information on blockchain-based 

solutions can be found here in the interview 

with Andreas Kötter. 

17 

about the product can be requested. It is up to 

the manufacturer which information is provided 

and to what level of detail. In this model, everyone 

remains anonymous and retains power over 

the transmission of their data. All communication 

partners are also anonymized. 

other product- related and relevant information 

“on demand,” but also to get paid for this additional 

service from the perspective of the component 

LCA provider. As this can be an additional 

revenue driver, it has a positive impact on the 

quality and resilience of this information. 

Read more about 

DIBIChain. 

WHAT DOES THIS MEAN FOR THE LIFE 

CYCLE ASSESSMENT OF A PRODUCT? 

For the life cycle assessment of a product, this 

means that all information from the entire supply 

chain is available. It provides a much higher 

level of transparency for the product concerned. 

The ability to request, for example, an LCA of a 

specific component on the supply chain also creates 

added value, as this data itself no longer 

needs to be collected or extrapolated. This results 

in the potential to not only share these and 

CONCLUSION 

As a growing number of companies are confronted 

with sustainability and the introduction 

of the Supply Chain Due Diligence Act, and this 

work can only be solved within whole supply 

chains, our approach was to create a platform 

for exactly this, combining data protection, 

product secrecy and supply chain transparency 

for a transformation towards sustainable product 

development. 

CONTACT 

Andreas Kötter 

andreas.koetter@capgemini.com

ZAL GMBH 

Martin Gromniak from ZAL 

GmbH’s automation team works 

towards certifiability of AI in 

an aviation context. 

18 

WOULD 

YOU FLY AI? 

HOW TO CERTIFY 

AI SYSTEMS 

Listen to the audio 

version of this text. 

In aviation there are high hopes for AI. Potential 

applications range from runway recognition 

to the autopilot of the future. 

Other applications could be the planning of 

consumption-optimized flight routes or visual 

quality control during aircraft assembly. 

However, in order to be applied in aviation, 

procedures must be developed to certify 

AI systems and thus prove their safety. 

A key component of certification is the explainability 

of AI algorithms. This means that the decisions 

made by the AI must be made comprehensible 

to humans. Explanations addressed to 

a user enable him or her to check the AI’s decisions 

for plausibility and to better understand 

the system. 

LEARNING TO IDENTIFY LANDING SITES 

FOR DRONES 

In the project VeriKAS (LuFo VI, funded by the 

Germany Federal Ministry for Economic Affairs 

and Climate Action), ZAL GmbH and other partners 

address the question of how AI systems 

can be made certifiable and what role explanations 

can play in this. In the project, two use 

cases are developed in which AI supports humans 

in decision-making.

WOULD YOU FLY AI? HOW TO CERTIFY AI SYSTEMS 

A KEY COMPONENT OF CERTIFICATION IS 

THE EXPLAINABILITY OF AI ALGORITHMS. 

A 3D version of Hamburg Altona is the virtual training 

environment for the drone’s neural network. 

AI support for drone operators: identifying the perfect 

landing spot made easier. 

CONTACT 

Dr. Felix Berteloot 

felix.berteloot@zal.aero 

The first use case is the automatic detection of 

possible landing sites for a drone in an urban 

area. The aircraft is equipped with a camera for 

this purpose and the captured images with it are 

evaluated by a neural network. The operator of 

the drone is then shown a map with possible 

landing sites. In addition, for each possible landing 

site there is a compact explanation of which 

criteria were relevant for the evaluation, for example 

the flatness of the ground or the recognition 

of the surface being a roof or a green area. 

Based on this information, the drone operator 

selects a landing point. The drone then performs 

the landing maneuver using a (conventional) autopilot. 

For the training of the neural networks, 

a simulation environment is used, which contains 

an approx. half-square-kilometer 3D model 

of a part of Hamburg. In the simulation, the 

drone repeatedly performs landings, receives 

feedback on how good a selected landing point 

was, and thus learns to identify good landing 

sites over time. 

DETECTING FOREIGN OBJECTS 

The second use case is located in the aircraft 

production process. During aircraft assembly unwanted 

objects, so-called “foreign object debris” 

(FOD), are forgotten in the aircraft and later lead 

to damage. These can be tools, for example. For 

this use case, an AI is being developed that analyzes 

images from a camera depicting the assembly 

process, providing the production worker 

with information about where FODs are located. 

In addition, a comparison with known objects will 

indicate which FODs are involved. 

Based on the two use cases, a certification process 

will be developed that certifies the safety of 

AI applications and thus paves the way for the 

autopilot of the future. 

19


BIGGER, 

BETTER, 

VISIONARY 

ZAL is expanding in two steps, with an extension and a new 

building. The extension to the ZAL TechCenter is in full 

swing. The new building wing is scheduled to be available 

by next year – with new conference rooms and hangar 

space for collaborative projects as well as plenty of space 

for two DLR institutes. 

20 

Open Hangar Space 

The newly created hangar space will provide 

room for project-related research 

work by alternating partners. The advantages: 

ZAL integration with the greatest 

possible flexibility in terms of technical 

equipment, team size, and project time. 

Innovation Service 

ZAL offers engineering services 

on the topics of decarbonization, 

automation, and intelligent cabin 

and acoustics. 

Innovation managers support 

partners in close cooperation 

with specialist engineers from 

the idea to the prototype. 

Flex Offices 

Meetings, office work, events: here, partners 

can cowork flexibly and temporarily at ZAL. 

A particularly attractive feature is the proximity 

of hangars, laboratories, and the workshop.

ZAL TECHCENTER EXPANSION 

Anchor Tenant 

Two DLR institutes will move into the 

annex currently under construction: 

the Institute of System Architectures in 

Aeronautics and the Institute of Maintenance, 

Repair and Overhaul. 



21 

Ready to move in? 

Check out our live webcam.


In the end, the expansion 

will blend in with the overall 

overall architecture of ZAL, 

as though it had always been 

there. 

22 

THE FORMATION 

OF A CAMPUS 

“We are expanding ZAL according to the principle 

'bigger, better, visionary.' This means that 

we not only want to grow for our partners, but 

also offer more options!” says Roland Gerhards, 

CEO at ZAL GmbH. In practical terms, 

this implies that flex offices for coworking as 

well as a so-called Open Hangar Space for practical 

work will be created as a part of the newly 

developed space. The offer is meant to enable 

alternating parties to carry out temporary 

projects at ZAL. The composition of the teams, 

their size, the equipment needed and the duration 

of the use of the space can be flexibly 

arranged. If required, the ZAL Innovation Service 

offers technical support, e. g. in the area 

of prototype construction, or methodical coaching 

by innovation managers. 

In addition, ZAL is being expanded to include a 

startup ecosystem. Players from Hamburg’s innovation 

landscape form the basis of this. 

Their intention is to bundle existing synergies 

of the location and make them accessible for 

aviation in concrete projects on site at ZAL. For 

example, start-ups are brought together with 

coaching and funding programs and financiers, 

measures that are intended to support the settlement 

of technology- and hardware-savvy, 

mature start-ups. In this way, ZAL is to develop 

into a campus where start-ups can network 

with research partners and potential customers. 

The resulting new projects can be implemented 

on site in the flexible working environment. 

Any engineering support or agile 

coaching is available as needed. 

The expansion 

promises more creative 

space for researchers.

ZAL TECHCENTER EXPANSION 

In the future, collaboration with start-ups will play an increasingly important role at ZAL. 

23 

Where the brightest 

and most innovative ideas 

can flourish.


The Sustainable Aero Lab is one 

of the puzzle pieces that will 

eventually become the innovation 

ecosystem of ZAL. 

24 

Together with the expansion of the building 

the Sustainable Aero Lab will help to expand 

research and technology activities and at the 

same time strengthen international collaboration. 

Here, the Sustainable Aero Lab will be one 

of the channels to constantly connect start-ups 

worldwide with the facilities and stakeholders 

at ZAL. Ideally, this will result in a fully institutionalized 

pathway to ensure ZAL stays a place 

where the brightest and most innovative ideas 

can flourish through open innovation and collaboration. 

Together with Hamburg Aviation, 

ZAL has been an associated partner of the Sustainable 

Aero Lab since its inception. ZAL’s CEO 

Roland Gerhards was one of the first people to 

join the high-ranking panel of permanent Lab 

mentors. Since then, ZAL has connected directly 

with numerous international start-ups and 

welcomed several founders and mentors to 

the ZAL TechCenter already. Of those, several 

have asked to discuss potential collaboration, 

even including renting lab and office space or 

engaging in joint research projects. This is a 

best-case scenario come true, as it makes the 

ZAL community more diverse and more international, 

with an inclusive approach where all 

companies and institutions in the building 

profit from gaining access to new potential 

partners. 

Bringing together promising start-ups 

with experienced mentors.

ZAL START-UP ECOSYSTEM 

Over 50 com panies 

have already been 

accelerated in the 

program. 

25 

SUSTAINABLE 

AERO LAB 

Founded in December 2020, the Sustainable Aero Lab 

is the world’s leading fast-track program dedicated to 

accelerating companies in sustainable aviation. The 

Sustainable Aero Lab does this by globally identifying 

and bringing together promising start-ups with experienced 

mentors and investors in live sessions and 

one-to-one coaching, opening doors and finding customers, 

new projects, and partners. Participation in 

the Lab is free to all start-ups, and admissions roll 

without set starting dates. 

In the first two years since its inception, over 50 companies 

have been accelerated in the program, with 

numerous collaborations and investments made. Its 

mentors are highly recognized individuals from aviation, 

industries, and venture capital who are motivated 

to share their experience and help companies build 

a new ecosystem of sustainable aviation. 

In addition, Sustainable Aero Lab serves as a platform 

to publicly discuss and promote zero-emission aviation 

technologies, including developments such as SAF 

and hydrogen.

DLR 

26 

A selection of DLR concept aircraft. 

NEXT GENERATION 

AVIATION CONCEPTS 

Which technologies will be essential for future aviation? Facing revolutionary 

changes such as the requirement for climate neutral mobility, 

automated factories of the future and evolving demands of the global 

passengers, concrete scenarios are required to identify the potentials 

of technologies as well as the technology vectors and boundary 

conditions for technology development. With the need to exploit all 

synergies, holistic next-generation aviation concepts are being investigated 

at the DLR Institute of System Architectures in Aeronautics 

covering aircraft design, certification, manufacturing, operations, and 

infrastructure. More than 20 aircraft concepts are already available 

and permit, for example, a comparison of sustainable aviation fuel 

options with hydrogen direct burn and fuel cell solutions. In regional, 

national, and European collaborations, the most promising models 

are the basis for more detailed technology research and innovations 

in collaboration with partners. Like this, the concept planes are refined 

to become high-fidelity digital platforms for interactive technology 

research. At ZAL, joint research e. g. on hydrogen and future 

manufacturing are being conducted with partners such as Airbus, 

Lufthansa Technik, ZAL GmbH, Hamburg’s universities, and DLR institutes 

and start-ups. 

AT ZAL, JOINT RESEARCH IS BEING CONDUCTED 

WITH PARTNERS SUCH AS AIRBUS, LUFTHANSA 

TECHNIK, ZAL GMBH, HAMBURG’S UNIVERSITIES, 

AND DLR INSTITUTES AND START-UPS.

DLR SL RESEARCH AT ZAL 

AUTOMATED MANUFACTURING 

AND PLANNING IN HAMBURG 

A virtual factory helps to examine new aircraft configurations for 

their manufacturability and simultaneously optimize production at 

a time when no real aircraft is available. But even in a virtual factory, 

not everything is done digitally. That’s why last year DLR set up 

and tested partial aspects in the laboratories – together with Airbus, 

Diehl, Dassault, the universities in Hamburg and other industrial 

partners and start-ups – at the Center for Applied Aeronautics Research 

Hamburg (ZAL). To this end, DLR is making a robot-assisted 

Holistic solutions have been targeted since decades but today the 

decisive step-change is in reach: the digital thread. Across the entire 

aviation sector, digital models and data are becoming available e. g. 

in the context of Industry 4.0. It is becoming possible to create future 

aviation concepts as a system-of-systems and to concurrently incorporate 

aircraft design, manufacturing, and operations, for example. 

In order to tie the thread from various sources and standards and to 

make it exploitable in practical design, research is being conducted 

on digital engineering methods such as semantic web technologies, 

artificial intelligence and the magic link between model-based syspre-assembly 

station available to its project partners in the physical 

and digital world. Here, the experts test how collaborative robots 

automatically install the systems and assemble lager modules. The 

results flow directly into the algorithms of the virtual factory. This is 

a first step toward Industry 4.0, in which the virtual and real worlds 

are completely linked. The experimentally validated digital platform 

is established to explore future manufacturing technologies in particular 

for cabin and fuselage applications. 

27 

Test environment at ZAL TechCenter. 

Robot-assisted pre-assembly station. 

COLLABORATIVE 

DIGITAL ENGINEERING 

CONTACT 

Dr.-Ing. Björn Nagel 

bjoern.nagel@dlr.de 

tems engineering and multidisciplinary design optimization. DLR’s research 

in the ZAL TechCenter is pronouncing processes for the application 

of digital methods. With the ambition to reliably capture wide 

parts of the aviation system, it is not only required to link high-fidelity 

digital content but also to join all the different experts in collaborative 

digital engineering processes. The essential knowledge to interpret 

computing results and to formulate new design problems needs to 

be mobilized. Hosted in Hamburg, decentralized design processes 

with more than 20 partners have been demonstrated with 70 software 

tools and covering three levels of the supply chain.

DLR 

LISTENING CLOSELY 

CONTACT 

Ann-Kathrin Koschlik 

ann-kathrin.koschlik@dlr.de 

28 

In order to detect anomalies in the operation of technical components 

before system failures and damages occur, sophisticated 

on-board sensor technology is usually necessary. However, for unmanned 

aerial vehicles (UAVs) this poses a problem: the entire sensor 

system must be permanently installed on the vehicle. This reduces 

the remaining payload capacity and the overall efficiency. 

A new approach now aims to monitor the electric engines of UAVs 

during landing and take-off – without any on-board sensors. For this 

purpose, researchers from the DLR Institute of Maintenance, Repair 

and Overhaul are working on measuring the acoustic signature of 

UAV propellers. They fed a neural network with hundreds of sound 

recordings, enabling the algorithm to detect and evaluate anomalies 

itself. Basically, after learning what a healthy propeller should sound 

like, it can now detect possible damages to the rotor blades just by 

listening to them. ZAL provided support with an anechoic chamber – 

a small recording laboratory that DLR researchers equipped with various 

microphones to find the best possible setup. 

The long-term goal is ambitious: to be capable of performing system 

diagnostics even in non-protected environments such as on the 

apron without interrupting ongoing operations – a significant advantage, 

especially for large fleets. Operators would thus be able to 

carry out maintenance work precisely when irregularities are detected, 

instead of following a rigid time schedule. Other industries have 

also recognized the potential. Acoustic monitoring is already used in 

German chip manufacturing plants to make delicate processes more 

reliable. In aviation, it has the power to take maintenance a decisive 

step further and support autonomous UAV operation. 

Listen to two recordings from 

the ZAL an echoic chamber – one 

with a normal propeller, the 

other with a trimmed rotor blade. 

Can you hear the difference? 

A drone is prepared for audio recording in the 

anechoic chamber at the ZAL. 

DLR AT ZAL 

FUEL CELL LAB 

CONTACT 

Dr.-Ing. Christoph Gentner 

christoph.gentner@dlr.de 

The Energy System Integration department from 

DLR’s Institute of Engineering Thermodynamics investigates 

fuel cell propulsion concepts for aircraft 

applications at ZAL TechCenter. By combining experimental 

characterization of fuel cell systems and 

components with numerical methods, critical operating 

states as well as the influence of individual 

components on the overall powertrain system are 

examined. Thus, the Institute of Engineering Thermodynamics 

identifies technology gaps and upcoming 

research and development tasks to meet the strict 

requirements of the aviation industry. 

The combination of laboratory tests on fuel cell systems 

together with numerical calculations has proven 

itself in 2022. Among other challenges, we were able to 

improve our fuel cell aircraft propulsion system design 

methodology, AirFuCS-CALC (Aircraft Fuel Cell System 

Calculator). For example, measurement campaigns in 

our fuel cell laboratory regarding the operations of 

fuel cell stacks and their air compressor have helped to 

further validate AirFuCS-CALC. By scaling components 

of our laboratory fuel cell system to the requirements 

of regional aircraft in the Megawatt-power class, we

DLR SL RESEARCH AT ZAL 

THE HUMAN IN THE LOOP 

Extended reality not only offers guidance to the worker – it also enables 

the tracking of manual activities. 

HUMANS WILL PLAY A DECISIVE 

ROLE IN THE MAINTENANCE OF 

AIRCRAFT SYSTEMS FOR THE FORE- 

SEEABLE FUTURE. 

Whenever people are to be trained in the handling of safety-critical 

systems, simulations are the preferred choice. They are intended to 

reproduce real-life requirements in as much detail as possible, but 

without exposing people to danger. Pilots, for example, complete a 

large part of their flight training in simulators. Using a real aircraft 

would be far too risky and expensive. 

Training also plays an important role in aircraft maintenance. The DLR 

Institute of Maintenance, Repair and Overhaul is therefore intensively 

researching the possibilities of extended reality (XR) applications. The 

technology, which has experienced a lot of hype in recent years, by 

no means solves all problems, but it does create completely new possibilities 

for integrating people into complex processes. It helps with 

training, but also offers guidance and support in later maintenance operations, 

effectively incorporating the human into the loop. With XR, for 

example, data from ultrasound examinations can be visualized directly 

on components to guide maintenance personnel to the right place. 

First of all, however, intensive fundamental research is still necessary: 

for example, it must be clarified how realistically the systems 

shown in XR should be represented. And how do you actually measure 

realism in the first place? These questions do not see humans 

as mere end users, but rather as the starting point for system design. 

Accordingly, if processes adapt to people instead of vice versa, 

then ultimately the entire maintenance operation becomes safer and 

more efficient. Because – no one doubts this at present – humans 

will play a decisive role in the maintenance of aircraft systems for the 

foreseeable future. 

CONTACT 

Rahel Louise Schmied-Kowarzik 

rahel.schmied-kowarzik@dlr.de 

29 

were able to prove that air compressors could make 

the greatest contribution to reduce the mass of fuel 

cell powertrains for aviation applications. 

With these skills and know-how, the Energy System 

Integration department develops operating strategies 

and predicts system performance over the flight mission 

for electric aircraft propulsion with hydrogen and 

fuel cells. 

In order to integrate more complex systems such as 

multi-fuel cell systems (MFCS) into the AirFuCS-CALC 

design methodology, further test benches will be developed 

and operated in the coming year. The focus 

is on the dimensioning of ancillary units for MFCS and 

the dynamic properties of the overall system. 

Customizable test bench for aerospace fuel cell systems.

DASSAULT SYSTÈMES 

The team of Dassault Systèmes, DLR, and 

other partners stand next to a manufacturing 

cell for human-robot collaborative 

assembly, which is also part of the ECN 

testbed for sustainable aviation. 

Find out more about the Engineering 

Collaboration Network. 

30 

ENGINEERING 

COLLABORATION 

NETWORK 

CONTACT 

Dr. Sven Lammers 

sven.lammers@3ds.com 

The German Aerospace Center (DLR) is working 

with the tech nology company Dassault Systèmes 

on the Engineering Collaboration Network initiative 

to find out how industry can benefit from 

working together digitally. 

To do so, DLR and Dassault Systèmes set up the 

groundwork with the 3DEXPERIENCE software 

platform developed by Dassault Systèmes in ZAL 

at the end of last year. With the help of a cloudbased, 

integrated collaboration environment, all 

parties involved can work together, communi- 

cate, and thus directly track changes in aircraft 

design, for example. The common goal is to optimize 

the value creation process of the economic 

ecosystem of avia tion and aerospace in order to 

enable sustainable flying and thus meet the societal 

requirements for a climate-neutral future. 

This goal can only be achieved if innovative technologies 

and concepts are jointly developed and 

tested. Therefore, the initiative is inviting partners, 

especially at ZAL, to participate and share 

their ex pertise to achieve something greater.

ENGINEERING COLLABORATION NETWORK 

31 

Dassault Systèmes and DLR sign the Memorandum 

of Understanding at ILA 2022 (from left to right): 

Dominic Kurtaz, Managing Director Eurocentral at 

Dassault Systèmes, Anke Kaysser-Pyzalla, Chair of 

the DLR Executive Board, and Markus Fischer, DLR 

Divisional Board Member for Aeronautics.

AIRBUS 

32 

Virtual design reviews of the future iMOD validation platform. 

INTELLIGENT MODULAR ROBOTICS 

AND PRODUCTION DESIGN 

Looking into the future of manufacturing aeroplanes, 

the production of the fuselage will change fundamentally. 

High rates of automation and high volumes of production 

will create new technical challenges. To be prepared 

and to shape the future, we are developing and 

applying cutting-edge physical as well as digital technologies 

at ZAL TechCenter in Hamburg. We work on 

developing and maturing the right technologies and 

bringing bits and pieces together. As a result, the iMOD 

station will come to life at the end of 2023. It is the 

heart of the demonstration and will serve for both basic 

research and as an industriali zation platform. 

The core application of this station is the development 

of new ways to efficiently drill and fasten circumferential 

and longitudinal joints. Furthermore, its design resembles 

an actual production station to enable out- 

of-production-cycle training. Our goal is to use the 

gained knowledge for the production of the A321 XLR. 

The demonstration is accompanied by latest digital applications, 

such as modelling, mixed reality, virtual commissioning, 

and other cutting-edge technologies. 

By involving working students and graduates into the 

project we develop a new generation of young professionals 

working on a new level of future automation 

and digitalization. We are proud to say that five Ph.D. 

theses and various Bachelor and Master theses were 

compiled within this framework. 

iMOD is a joint research approach by Helmut-Schmidt 

University, Airbus, ZAL GmbH, CTC GmbH, HDE Consult 

GmbH, IFA University of Hanover, Fraunhofer IFAM, and 

Capgemini. 

Read more 

about iMOD. 

CONTACT 

Sara Abshagen 

sara.abshagen@airbus.com

IMOD & MIXED REALITY DEMONSTRATOR 

THE DIGITAL TRANSFORMATION IS 

HAPPENING FROM PLANNING TO 

EXECUTION – END2END. 

MIXED REALITY 

DEMONSTRATOR 

Mixed reality and smart tool applications tested in A320 MSN4. 

Augmenting the real world with additional information in order to 

simplify tasks has been an Airbus ambition for several years. The Fuselage 

Industrial Line environment is close to serial conditions, enabling 

development and demonstration without disturbing the production. 

Using early versions of software, we are able to showcase it 

and exchange with our customers in engineering and on the shopfloor 

to further improve the system to their needs. 

Use cases are guided work instructions that are displayed in IoT devices. 

Even the location of parts for installation purposes is visible 

directly in the field of view of the worker. This is one great example, 

where early feedback is needed in order to ensure mature technologies 

and acceptance by the future user. 

Another example is individual context allocation and computer vision 

applications paired with smart tools, such as a screwdriver. The system 

provides additional data to guide through the manufacturing process 

and support quality checks. This is not only to avoid mistakes, but is 

also interesting to use and improves the safety of our colleagues, 

which leads to a further use case: the ergonomic analysis. Combined 

with virtual reality applications, we support engineering to find solutions 

that lead to avoidance of unhealthy movements. System developers 

and future applicants work hand in hand to help bring innovation 

to our production lines. The digital transformation is happening 

from planning to execution – End2End. 

33 

Test of new augmented reality applications in an industrial environment. 

CONTACT 

Holger Krupp 

holger.krupp@airbus.com


WHAT MAKES AN AIR 

CRAFT CABIN SMART? 

Picture a flight where you can control your individual cabin experience: 

lighting, temperature, and entertainment options – everything is personalized 

to your liking. Smart monitoring supports the crew and ground personnel, 

thereby also reducing turnaround times. The backbone of this vision 

is the integration of so-called smart technologies into the digital 

cabin system. But have you ever tried to integrate a new device from a 

third party into your digital smart home? Well, that situation is not too 

different from a modern cabin. Imagine speakers for audio effects, microphones 

for active noise cancellation, or sensors for crew support in cabin 

operation: whatever innovations developers want to bring to the cabin, 

the devices are to be integrated into the cabin network without interfering 

with other functionalities. And that’s where the recent projects of ZAL 

GmbH come in. 

34 

A Digital Cabin Multi-Tool 

To connect end devices to a digital cabin network, ZAL GmbH 

developed the ZAL Endpoint. The Endpoint represents an interface 

between network nodes, like the DELIA module, and other 

end devices. It features a single-pair Ethernet interface for lowweight 

wired connectivity, the Zephyr Operating System for real-time 

functions and fast development. The ZAL Endpoint provides 

various connectors and is flexible and adaptable to a 

multitude of use cases. At the same time, it supplies power to 

end devices and also ensures real-time data transmission using 

Time Sensitive Networking (TSN). 

Endpoint Performance 


use cases here. 

Some applications require a more powerful edge computing device. 

For example, when complex video effects are to be displayed 

or when a camera is to be used to detect unwanted behavior 

or forgotten objects. For those more demanding use 

cases, ZAL GmbH developed a more powerful version of the ZAL 

Endpoint: the Endpoint Performance. It is based on a mobile 

dual-core CPU with an AI co-processor. Experimenting with 

complex use cases in a digital cabin has never been easier! 

Automated Testing of 

Cabin Network Systems 

When a new digital technology is integrated into 

an aircraft cabin, it needs to be thoroughly tested. 

ZAL GmbH experts work on streamlining the testing 

process by building an automated pipeline for 

continuous integration of test routines for a cabin 

network. For example, when new cabin technologies 

or sensors are being developed for the cabin, 

their software can be automatically built, distributed, 

and tested. This way, the development cycles 

can be reduced.

WHAT MAKES AN AIRCRAFT CABIN SMART? 

ENDPOINT 

DELIA MODUL 

CONTACT 

Dr. Leonid Lichtenstein 

leonid.lichtenstein@zal.aero 

Processing 

Big Data 

A single unified network connects all devices 

seamlessly, replacing disconnected and incompatible 

individual networks. The innovative DELIA 

modules make this possible, executing all applications 

from lighting control to in-flight entertainment 

and transmitting data at high speeds 

through a shared fiber optic cable. This technology 

significantly reduces weight by eliminating multiple 

cables, resulting in more fuel-efficient flights. 

Time Sensitive Networking (TSN) ensures that 

data is fully received in real-time, even in the situation 

when a cable is damaged. 

35 

Read more 

about DELIA. 

Priority on the Data Highway 

Time Sensitive Networking (TSN) is a collection of industry standards that extends conventional 

Ethernet with various procedures and protocols. The idea is to avoid delays or losses 

in data transmission and thus guarantee high reliability – especially when the network load 

is high. In the cabin, TSN enables a shared network for different systems. One example is 

the Passenger Announcement System, which is only allowed to transmit with minimal delay 

to avoid echo effects and thus ensure easily understandable voice transmission. This is 

particularly relevant when it comes to passenger safety announcements. Data traffic is 

therefore prioritized. 

Read more 

about TSN.

AES 

CREATING 

SOLUTIONS WITH 

TOMORROW’S 

TECHNOLOGY 

36 

The Bremen-based company, AES Aircraft 

Elektro/Elektronik System GmbH, has come 

a long way since its inception a quarter of a 

century ago. Today it is a renowned global 

supplier of aerospace and maritime products. 

Founded in 1997 with the vision of implementing 

customer needs in the rapidly 

expanding aviation industry competently 

and efficiently, AES products can now be 

found in numerous passenger aircraft and 

VIP jets. 

Its product portfolio ranges from LED lighting 

systems and power supplies to communication 

and information systems for aircraft cabins. 

Along with highly innovative and comprehen sive 

products, the company’s success is thanks to its 

electronic design services. The company’s electrical 

engineering services include integral electrical 

designs as well as consulting and support 

in the area of qualification and certification. 

INNOVATIVE AVIATION TECHNOLOGIES 

MADE IN NORTHERN GERMANY 

Its corporate headquarters are located in Bremen, 

and the company maintains a second location 

in Hamburg. The Hamburg branch has 

been based in the ZAL Center of Applied Aeronautics 

Research since 2021. “Memberships 

and engagement in various aviation associations 

such as AVIASPACE, Hamburg Aviation, 

and Hanse-Aerospace e.V. demonstrate close 

ties between both Hanseatic cities (Bremen and 

Hamburg), including the desire to play an active 

role in strengthening the aerospace industry in 

northern Germany,“ explains Dr. Jörn Burkert, 

CEO of AES. “The leading technolo gical research 

and development center for civil aviation pro-

CREATING SOLUTIONS WITH TOMORROW’S TECHNOLOGY 

vides the perfect environment for our vision.“ AES 

has also already recorded its first successes at 

ZAL as part of a cooperation with Airbus in the 

Beluga second life project. 

ITS AIM IS TO DESIGN AIRCRAFT CABINS 

OF TOMORROW DIGITALLY WITH SYSTEMS 

WORKING CLOSELY TOGETHER, USING 

ITS INNOVATIONS AND TECHNOLOGIES. 

SOPHISTICATED SOLUTIONS FOR PREMIUM 

CUSTOMERS AND EXCEPTIONAL AIRCRAFT 

Anyone flying on holiday in an Airbus aircraft will 

almost certainly encounter a product from AES 

GmbH. This is not only true on holiday flights, but 

business flights, too – leading German politicians 

come across AES’ products as well. Two out of 

three Airbus aircraft use products developed on 

its two locations, in Bremen and Hamburg. There 

have been numerous innovations at AES over the 

past 25 years. The first pure white LED light, for 

example, was developed and approved for Airbus 

in Bremen. AES, led by its team at the ZAL 

TechCenter, handles the complete equipping of 

lighting systems and special requests, especially 

for private jets and custom orders. 

Germany’s federal government has a fleet of aircraft 

on standby, meaning high-ranking German 

politicians benefit from AES lighting during their 

foreign state visits. The most modern government 

aircraft relies on AES technology – namely 

the A350-900, which entered into operation 

at the end of 2022. The Hamburg location fulfills 

the wishes of many exclusive customers. 

This could be a sparkling night sky made of LED 

lights embedded into the ceiling of the aircraft, 

lamps fitted with golden frames, or specially illuminated 

make-up mirrors. Equipment such as 

fax machines and microwaves can only be put 

into operation in an aircraft with a great deal of 

know-how and individual conversions. These are 

also requirements that AES has already implemented 

into VIP aircraft. 

DIGITIZATION AND INCREASINGLY 

COMPLEX SYSTEMS FOR THE AIRCRAFT 

OF TOMORROW 

Systems have become more and more complex 

over the years – and so have AES’ designs. Lighting 

systems have been complemented by digital 

control systems and in-flight entertainment systems. 

Many new electronics components have 

made way to its portfolio: network technology, 

communication equipment and power management 

systems. Its aim is to design aircraft cabins 

of tomorrow digitally with systems working 

closely together, using its innovations and technologies. 

COMBINING CREATIVE IDEAS WITH 

SKILLED ENGINEERING 

AES is currently working on touchless gesture 

controlled lighting and Li-Fi data transmission. 

This relatively new and unused technology does 

not transmits data via radio waves (WIFI), but 

rather with undetectable light pulses from lamps. 

This is advantegous because fewer cables are 

required, making an aircraft lighter, and at the 

same time eliminating disturbing radio waves. A 

newly developed spotlight by AES can be turned 

on and off as well as dimmed via hand gestures. 

AES’ Touchless Flush Switch is a seamless solution. 

The integrated IR sensors track hand movements, 

which activates the switch. This provides 

a contact-free solution, reducing the spread of 

bacteria and viruses on board the aircraft. 

FUTURE-ORIENTED THINKING 

AES is a forward-thinking company, which continually 

adapts itself to meet the challenges of the 

changing times. As a result, the goal of achieving 

energy neutrality by 2025 is a major objective for 

the company. Last year, its Bremen headquarters 

was equipped with a rooftop photovoltaic 

system. AES’s affiliate Solares Energy GmbH, installed 

this system. 

The AES team is also venturing into equipping 

satellites and ships, in addition to its work in the 

aviation sector. “Utilizing our core competencies 

with electronics, we strive to extend our expertise 

into other industries,” says Vahit Ezer-Hagemann, 

CEO at AES. 

CONTACT 

Oliver Wulf 

oliver.wulf@aes-aero.com 

37


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! 

38 

LISTEN ON 

EPISODE #1: ROLAND GERHARDS 

ACCELERATING 

INNOVATION 

TOWARD NET 

ZERO 

Our first episode is 

with Roland Gerhards, 

CEO of ZAL in 

Hamburg. Roland is a veteran of the aviation industry, having 

worked at Airbus for 15 years on the A380, A350, and A330 

programs. ZAL is one of the world's foremost centers for applied 

aviation research. In this episode Roland Gerhards 

gives insights into what it’s like to run an institute that is at 

the forefront of R&D in sustainable aviation, why it's important 

to offer engineers free lunches, and how ZAL approaches 

R&D to make it faster and more productive.

HAMBURG AVIATION GREEN PODCAST 

How can changes in airport 

operations contribute to aviation’s 

goal of reaching net 

zero? What role should offsets 

play? What can airports 

do to decarbonize? Has the 

Covid pandemic influenced 

the conversation around sustainable aviation? These 

were among the many pressing questions we discussed 

on this episode with Michael Eggenschwiler, CEO at 

Hamburg Airport. With many years of experience in aviation 

both at airlines and at northern Germany's largest 

airport, Michael brings his own personal view to the 

wider conversation around sustainability. 

EPISODE #2: MICHAEL EGGENSCHWILER 

MAKING 

AIRPORTS MORE 

SUSTAINABLE 

39 

EPISODE #3: MARIO VESCO 

START-UPS: 

FASTER PATHS 

TO NET ZERO 

While the aviation industry aims to reach 

net zero by 2050, many of the technologies 

needed to get there are still years away. 

What role can start-ups play in getting 

those crucial developments available faster? 

How can we actively harness the creativity 

of young businesspeople and researchers? 

Are start-ups better at innovation 

than corporations? How can government 

create better conditions for them to flourish? 

Answering these and many more questions 

on this episode is Mario Vesco, Venture 

Manager at Sustainable Aero Lab. The 

lab’s aim: speed up innovation and R&D 

around decarbonization. The lab has 

worked with 50+ start-ups to date.


40 

THE FUTURE OF 

AVIATION IS ABOUT 

ACOUSTICS, TOO! 

CONTACT 

Dr.-Ing. Patrick Cordes 

patrick.cordes@zal.aero 

Cabin noise is a complex issue familiar to 

everyone who flies. Whether it’s the captain’s 

hard-to-understand voice, singing 

party travelers in the back row, noise from 

the galley or the lavatory door, the already 

colorful soundscape is overlaid with the 

loud drone of the engines. But how can 

cabin noise be tackled? ZAL GmbH’s acoustics 

expert, Patrick Cordes, explains how 

acoustic simulations ensure a smooth travel 

experience and what insights we can use 

from the development of VIP cabins for future 

hydrogen airplanes. 

When it comes to innovations in aviation, 

the topic of sustainability is omnipresent. 

The question arises as to whether acoustics 

will still play a role in the future? 

CORDES A very big one, actually! We are currently 

focusing on hydrogen to make aviation more 

sustainable. This means aircraft will have to 

change. Due to their higher efficiency, we are 

currently seeing the rise of short to mediumrange 

aircraft concepts using propellers. For instance, 

Airbus has introduced an open-rotor 

concept as part of their ZEROe strategy. These 

types of engines produce very different noise 

spectra than the current jet engines. Consequently, 

we must rethink acoustics and the design 

of noise control onboard. 

Why is acoustics important, isn’t it a secondary 

issue? 

CORDES Two points are crucial here. First, acoustics 

research not only makes aircraft cabins quieter 

but also lighter. We investigate which 

acoustic measures, used in which areas, achieve 

what effects. Thus, we can apply the measures 

more effectively. This has the potential to save 

weight and therefore fuel. A tangible effect for 

the overall sustainability of aviation. Secondly, 

the success of these new airplane concepts will 

be the acceptance among travelers. Noise level 

plays an important role, influencing the comfort

THE FUTURE OF AVIATION IS ABOUT ACOUSTICS, TOO 

“Would passengers choose to ‘fly hydrogen’ 

if these aircraft were significantly louder? 

And this is exactly where we can help.” 

Patrick Cordes, Head of Advanced Materials 

we experience during a flight. Would passengers 

choose to “fly hydrogen” if these aircraft were 

significantly louder and the conventional option 

was available? I doubt it. And this is exactly 

where we can help. 

How will modern acoustics research meet 

this challenge? 

CORDES Good cabin acoustics are the result of a 

long chain of various individual precautions, 

ranging from seat fastening to cabin lining. In 

acoustics, we speak of transfer paths, i. e., ways 

that a noise can take to get from its source into 

the cabin. Based on the type of transfer path, different 

measures need to be taken in order to 

yield a reduction of the transferred energy. These 

measures may be classical glass wool insulations, 

but also novel acoustic metamaterials, active 

noise control measures, or new vibration insulations 

may also play crucial parts in the future. 

How do you identify these transfer paths? 

CORDES To simplify, there are two ways that 

noise (we describe it as energy) can enter the 

cabin: through air and through vibration. It’s important 

to determine how noise is transferred 

and how much each path contributes to the 

overall noise level. We use a combination of experiments 

and simulations to do this. With simulations, 

we can test different solutions before 

the cabin is built, allowing us to take measures 

to reduce noise from the start. 

With new engines and presumably additional 

hydrogen tanks, a hydrogen aircraft 

might have a completely different cabin design. 

How do you simulate something unknown? 

CORDES We need flexible approaches for these 

challenges that can quickly adapt to new materials 

or aircraft designs. Currently, we are developing 

a simulation workflow based on VIP cabins. 

(Entirety Project, ZAL in collaboration with 

Lufthansa Technik and the Hamburg University 

of Applied Sciences). VIP cabins typically have 

unique customized designs and often include 

unusual components. One of the main challenges 

in developing VIP cabins is that they are 

typically built only once, which means that experimental 

validation can only take place after the 

cabin is completed. Consequently, an accurate 

simulation is crucial. Our methodology is to combine 

various sub-simulations at the material and 

component level, and ultimately to create a complete 

simulation of the cabin. 

Thus, simulation can help to accelerate any cabin 

development and to forecast the effect of new 

components on the cabin acoustics. And at the 

same time, it provides passengers with a pleasant 

travel experience – hopefully in hydrogen - 

powered aircraft soon, too. 

41 

A numerical model of a cabin sidewall used for acoustics simulation.

FRAUNHOFER IFAM 

SMART AIRCRAFT 

ASSEMBLY 

42 

Prototype for joining upper and side panels. 

As part of Fraunhofer’s commitment to 

push the boundaries of aircraft manufacturing, 

Fraunhofer IFAM collaborates with 

industry leaders such as Airbus as end user 

and project lead, Broetje Automation, CENIT, 

and 3D.aero. Under tight cooperation, we 

have developed a fully integrated cyberphysical 

facility that automates the assembly 

of large fuselage composite panels. 

The first step is to extract geometrical data from 

the panels via cameras and to compare these 

with nominal data. Based on the result ing deviations, 

deformation movements are calculated for 

the grippers holding the panels by using algorithms 

to predict forces. This is then repeated 

iteratively until the measured deviation is within 

manufacturing tolerances. All this happens while 

the status of the facility is being monitored 

through a digital factory twin. Furthermore, the 

developed system includes several innovative 

features, such as: 

• a multi-camera-based markerless photogrammetry 

system 

• adaptable and modular grippers and 

actuator systems for fuselage-panel handling 

• an information system capable of 

deter ministic real-time communication 

• an automated assembly procedure that 

complies with built-in stress requirements 

Likewise, our collaboration with the ZAL GmbH 

in Hamburg has been instrumental in the development 

of this prototypical system, which represents 

a significant advancement in aircraft 

manufacturing technology.

SMART AIRCRAFT ASSEMBLY 

LIKEWISE, OUR COLLABORATION WITH THE ZAL GMBH IN 

HAMBURG HAS BEEN INSTRUMENTAL IN THE DEVELOPMENT 

OF THIS PROTOTYPICAL SYSTEM, WHICH REPRESENTS A 

SIGNIFICANT ADVANCEMENT IN AIRCRAFT MANUFACTURING 

TECHNOLOGY. 

MARKERLESS PHOTOGRAMMETRY 

The markerless photogrammetry system developed 

in cooperation with 3D.aero uses multiple 

images to measure the shape and position of the 

parts, eliminating the need for permanent laser 

trackers, which represent the state of the art. In 

so doing, the time-consuming and error-prone 

manual fixing of reflector targets has been avoided 

and replaced by a system of 3D.aero’s 

SurfEyes that can measure and process data in 

short over one second versus several minutes. 

ADAPTIVE SHAPE AND POSE CORRECTION 

WITH ADAPTIVE MODULAR PANEL HAN- 

DLING FIXTURE 

The use of adaptive and modular concepts in 

handling fuselage panels enhances assembly 

flexibility and efficiency. This involves the modular 

gripper system and Broetje’s Eco-Positioner, 

which can correct component shape and position 

in terms of force. 

43 

INFORMATION SYSTEM WITH REAL-TIME 

HARDWARE AND SOFTWARE INTERFACES 

A deterministic real-time communication system 

has been developed by Fraunhofer IFAM using 

standard components and a real-time operating 

system (RTOS). It is capable of transmitting data 

between critical systems reliably and accurately 

without the need for proprietary controllers or 

communication boards, making it highly scalable 

and customizable for a wide range of applications. 

This system represents a significant advancement 

of real-time data communication for 

the IoT era and offers numerous benefits, including 

improved system performance, reduced 

maintenance costs, and increased flexibility in 

hardware and software integration. Additionally, 

the integration of the OPC-UA standard for the 

non-critical components and its combination 

with semantic data models and a digital twin as 

done by CENIT enables unified information models 

and data analytics. 

3D.aero’s SurfEyes measuring the panels back interface edge.

FRAUNHOFER IFAM 

Broetje’s modular adaptive 

gripper system. 

44

SMART AIRCRAFT ASSEMBLY 

Watch a video about 

the Fraunhofer IFAM 

project BiSconA. 

Fraunhofer IFAM’s representation of markerless 

photogrammetry-based shape correction. 

The automated assembly process is designed to 

reduce the risk of damage or failure during assembly 

by accounting for the internal stresses of 

the parts. This is achieved by adaptive correction 

algorithms, which ensure that the fuselage panel 

is correctly aligned and shaped during assembly. 

Therefore, an empirical model has been developed 

to predict induced forces and plan dependent 

actuator movement iteratively, considering 

the interactions between the handling system, 

panel shape, and measured forces. This approach 

enables the assembly process to adapt 

to variations and unique character of the panels, 

while ensuring that the built-in stresses of the 

materials are accounted for. Overall, the use of 

these adaptive shape and pose correction algorithms 

represent a significant advancement in 

the field of aircraft manufacturing, with the potential 

to improve the efficiency and reliability of 

the assembly process. 

Looking into the world of tomorrow, the utilization 

of deep learning and neural networks to 

improve the accuracy of the force predic tion in 

the shape adjustment process would reduce 

lead times and stress. The use of structured 

lighting to measure panel interfaces, as initiated 

by 3D.aero, would provide more precise and accurate 

data directly on the interfaces of the panels, 

further enhancing the accuracy of the assembly 

process. 

Fraunhofer IFAM’s vision of mobile joining 

of sections. 

Fraunhofer IFAM’s next step is the joining of fully 

assembled sections and the mobilization of 

the process through modular handling systems 

and automatic guided vehicles (AGVs). This approach 

offers numerous benefits, including increased 

flexibility, possibly faster assembly 

times, and improved shopfloor efficiency. Therefore, 

this will be a key component of upcoming 

R&D projects, which aim to develop a mobile assembly 

line for aircraft manufacturing. 

The presented investigations were conducted as 

part of the project BiSconA (“Built-in-Stress conformal 

Assembly”; LuFoV3-FKZ: 20W1724B), 

funded by the Federal Ministry for Economic Affairs 

and Climate Action. Project partners are Airbus 

Operations GmbH, BA Assembly & Turnkey 

Systems GmbH (Broetje Automation), CENIT AG, 

Fraunhofer IFAM, 3D.aero GmbH. 

45 

CONTACT 

Daniel Valencia 

daniel.valencia@ifam.fraunhofer.de

HAW 

RESEARCH 

The ZAL TechCenter offers HAW Hamburg the 

ideal platform for getting started with experimental 

research in the field of hydrogen. 

46 

FOR SUSTAINABLE 

AIRCRAFT 

The Hamburg University of Applied Sciences 

(HAW Hamburg) qualifies young aeronautical 

engineers with Bachelor of Engineering 

and Master of Science degrees as well as 

PhDs in cooperation with partners. Sustainable 

aviation is playing an increasingly important 

role in professional education and 

research. Students are familiarized with research 

processes at an early stage and are 

also given the opportunity to develop the 

necessary technology skills. Several research 

projects with sustainability in mind 

have been launched recently. 

OPTIMIZING THE HYDROGEN 

AIRCRAFT WITH MODEL-BASED SYSTEMS 

ENGINEERING 

Liquid hydrogen as aircraft fuel offers the potential 

for a significant reduction of emissions. A ma- 

jor challenge of hydrogen aircraft system development 

is the evaluation of different system 

architectures regarding system and operational 

requirements as well as lifecycle costs. In the 

framework of the MIWa research project, HAW 

Hamburg and the DLR Institute of System Architectures 

in Aeronautics (DLR SL) together with 

Centerline Design GmbH, are establishing a digital 

model of a commercial aircraft with integrated 

liquid hydrogen systems using the graphical 

systems modeling language SysML among the 

model-based systems engineering approach. 

The resulting models will be modular and linkable 

with each other in order to obtain a digital, 

parameterized and reconfigurable system architecture 

description. Thus, the consequences of 

different mission objectives as well as system requirements 

can be estimated on a model-based 

foundation at a very early stage of development.

RESEARCH FOR SUSTAINABLE AIRCRAFT 

A MAJOR CHALLENGE OF HYDROGEN AIRCRAFT SYSTEM 

DEVELOPMENT IS THE EVALUATION OF DIFFERENT SYSTEM 

ARCHITECTURES REGARDING SYSTEM AND OPERATIONAL 

REQUIREMENTS AS WELL AS LIFECYCLE COSTS. 

SUSTAINABILITY REQUIRES 

NEW AIRCRAFT CABINS 

In the project ReCab HAW Hamburg studies the 

resource-efficient and sustainable aircraft cabin 

together with Lufthansa Technik AG, Diehl Aviation 

and TUHH. In complex socio-technical systems, 

such as aircraft cabins, the assessment capability 

of cabin equipment and processes is 

crucial. Therefore, HAW Hamburg aims to develop 

a holistic cabin concept of the future. By considering 

today’s medium- and long-haul flights 

and new technological and procedural approaches, 

new innovative concepts will be developed 

that will minimize the resource consumption, reduce 

complexities or increase the involvement 

of passengers in delivery process. With a new 

sustainability navigator, the impact assessment 

of technological and procedural approaches will 

be easier in future. 

The CATECO project spotlights the acoustics of 

future aircraft cabins. Future hybrid-electric regional 

and short-haul aircraft will be powered by 

propellers. However, propeller-driven aircraft 

pose a major challenge due to the high noise levels 

expected in the cabin. Active noise control 

may reduce this noise very efficiently. Together 

with Airbus and DLR SL, HAW Hamburg is researching 

the integration of active noise reduction 

in future cabin management systems. Such 

cabin management systems will offer common 

communication and computing platforms that 

are able to host various cabin services, such as 

public address, passenger calls as well as lavatory 

and galley management. Key technologies are 

high data rates and open industrial communication 

standards like Time Sensitive Networking. 

The main project idea is to move the system intelligence 

from a central instance to the actuators 

on the edge of the system. 

Researchers at HAW Hamburg develop model-based methods 

for the design of hydrogen aircraft systems. 

A NUCLEUS FOR OUR 

GREEN AVIATION LAB 

HAW Hamburg plans to expand its joint research 

with research partners from ZAL in the next 

month. For example, a prerequisite for flying with 

hydrogen is measuring the amount of liquid hydrogen 

stored in the aircraft. Today, there are no 

fuel sensor technologies available that meet the 

requirements of certification and cryogenic temperatures. 

To achieve this goal, HAW Hamburg 

and Autoflug GmbH will develop fuel sensors to 

measure the mass of liquid hydrogen in the 

framework of the Precise project. In the joint project 

BeHyPSy with ZAL GmbH and HSU, an innovative 

concept of a hydrogen based hybrid -electric 

powertrain for light sport aircraft will be investigated. 

HAW Hamburg will support the system development 

in design, optimization, and testing 

using numerical and model-based methods. 

With these new projects, HAW Hamburg aims to 

establish new test rigs in the Open Hangar Space 

of ZAL II to intensify the collaboration with its 

partners. In addition, academic courses with 

young students may also take place in this application-oriented 

research atmosphere to set new 

impulses in the ZAL TechCenter. 

CONTACT 

Prof. Dr.-Ing. Kay Kochan 

kay.kochan@haw-hamburg.de 

47

IDS 

IN THE SKY, 

ON LAND, 

AND AT SEA 

48 

“We really appreciate the short links to 

the other ZAL-located companies and 

are looking forward to keeping up the 

successful collaboration in many further 

joint projects and R&T projects.” 

Torsten Kanitz, CEO at Industrial Design Studio Hamburg

IN THE SKY, ON LAND, AND AT SEA 

THE RESEARCH AND DEVELOPMENT OF INNO- 

VATIVE PRODUCTS IS CLOSELY LINKED TO THEIR 

APPEARANCE. SUSTAINABLE PRODUCT DESIGN IS 

OUR CONTRIBUTION TO PRESERVING OUR EN- 

VIRONMENT FOR FUTURE GENERATIONS. AT THE 

INTERFACE BETWEEN RESEARCH RESULTS AND 

EXPLOITATION FOR MARKET LAUNCH, WE HELP 

TO MAKE THE PRODUCT ATTRACTIVE TO THE 

LARGEST POSSIBLE TARGET GROUP. 

“Our focus is intelligent 

industrial design: deeply 

understanding our 

customers’ projects and 

needs, finding highest quality 

solutions and supporting 

them to get exactly what they 

are happy with.” 

49 

Imme Kuhnert, Head of Industrial Design & Lighting Simulation 

Find out more about 

Industrial Design 

Studio Hamburg. 

CONTACT 

info@ids-hamburg.com


50 

ENABLING 

HYDROGEN FOR 

AVIATION & 

MARITIME 

Currently, many companies want to make 

their business more sustainable and future-proof. 

The hydrogen sector is very 

promising here. But many players lack relevant 

know-how. In addition, shortage of 

skilled personnel, as well as missing access 

to gas supply and test facilities for hydrogen 

jeopardize the practical realization of 

these business visions. Thanks to ITZ, there 

is a solution here. 

ITZ NORD EXPLAINED 

The Hydrogen Innovation and Technology Center 

(Innovations- und Technologiezentrum Wasserstoff 

– ITZ) is implemented by the Federal 

Ministry for Digital and Transport (BMDV). There 

are four ITZ sites located in Germany. Their aim 

is to create a development, research, and testing 

environment, that are not or not sufficiently 

available on the market yet. Be sides, existing 

networks are to be streng thened and established 

in order to pool knowledge and enthusiasm 

for hydrogen. The target groups are startups, 

founders, and small and medium-sized 

enterprises. On an international level, the ITZ is 

to help set technical and economic standards. 

ITZ NORD ON AVIATION & MARITIME 

The ITZ Nord (Bremen/Bremerhaven, Hamburg, 

and Stade) mainly concentrates on its core areas 

of maritime and aviation. The focus is on 

the development and integration of fuel cell 

systems and corresponding components, the 

hybridization of drive trains, refueling concepts, 

logistics, storage and processing of green 

hydrogen and hydrogen-based fuels, as well as 

the testing of components and systems. Furthermore, 

competences on standardization 

and certification issues are pooled with the 

close involvement of classi fication societies. 

Watch here how ITZ Nord 

enables aviation and 

maritime in hydrogen 

technologies.

ITZ – ENABLING HYDROGEN FOR AVIATION & MARITIME 

ZAL INNOVATION TALK – 5 Years From Now. 

Listen to this episode and learn about the 

synergies between aviation and maritime 

concerning hydrogen applications. 

H 2 

51 

ZAL GOES ITZ 

At ZAL TechCenter hydrogen experts provide technical advice 

and support for implementation of maritime and aviation 

projects. Moreover, interested parties have access to 

hydrogen test infrastructures, gas supply including gaseous 

and liquid H 2 

, N 2 

or O 2 

, and a prototype workshop. Networking 

opportunities with highly motivated in-house partners 

researching the same topics come free of charge.


FUELING 

HYDROGEN 

52 

The implementation of the ITZ is an important 

step in the development of a hydrogen 

ecosystem in Germany. The fact that aviation 

and maritime are being thought of together 

in Hamburg makes sense, because 

both industries are facing similar issues. 

They are systemically important parts of the 

global economy, are experiencing steady 

growth in traffic, and have been dependent 

on fossil fuels. Thus, both industries face the 

challenge of building a hydrogen infrastructure 

to become more sustainable. 

NEW FUEL MEANS NEW CHALLENGES 

A complex undertaking. After all, filling an aircraft 

or ship with a new type of fuel requires 

new types of equipment and infrastructure 

that are compatible anywhere in the world and 

at the same time meet safety requirements. 

For aviation, this means: EASA and FAA will 

have to agree on common standards for hydrogen 

systems, which will require extensive testing 

and research in advance. Due to the significantly 

higher volume of the new fuel, H 2 

will 

only make sense to use in aircraft in liquid 

form at -253 °C. But what does that mean for 

refueling and storage? Could existing gas pipelines 

be used for logistics? And can hydrogen 

be stored in large gas tanks at the airport so 

that it can only be liquefied before refueling? 

How costly and reliable would such a liquefier 

then be, and what would it need to look like for 

daily industrial use? What additional hardware, 

which may not even exist today, would still 

have to be built? 

SOLUTIONS ON THE WAY 

Some of these questions are being researched 

in the Hydrogen Aviation Lab by Lufthansa 

Technik, DLR, Hamburg Airport, and ZAL. The 

core of the lab is a former Lufthansa Airbus 

A320, which is being converted into the world's 

first demonstrator for refueling operations 

with hydrogen on this scale. 

Another player looking at hydrogen refueling 

is California-based Universal Hydrogen, founded 

by former Airbus technology chief and "Silicon 

Valley" scion Paul Eremenko. The idea 

here is to get hydrogen onto planes in retrofittable, 

cartridge-like containers – the advantage

FUELING HYDROGEN 

53 

being that airports would not have to build 

their own infrastructure. A major disadvantage 

would be a challenging logistics chain and a 

complex redesign in aircraft equipment. Irrespective 

of this, this solution would also first 

have to be certified by the FAA and EASA to 

open a market. The regulatory side thus plays 

a key role – as is so often the case in aviation. 

(AIR)PORTS WITH POTENTIAL 

However, part of the vision of zero-emission 

flying takes place on the ground. And this is 

where ground services at airports could play a 

decisive role in the economic success of H 2 

. 

After all, once the fuel is on site, it could also 

be used for other applications – for example, 

ground power units or aircraft tractors. It is also 

much easier to implement on the ground. 

Especially if it were possible to work permanently 

with gaseous hydrogen here, which 

does not have to be cooled down to -253 °C. 

The (air)ports have exciting potential for hydrogen 

applications and could have a significant 

impact on the profitability of the new hydrogen 

ecosystem. 

EVER THOUGHT 

ABOUT THIS? 

If we want to build a hydrogen ecosystem for aviation in 

Europe, we need far more airports equipped for hydrogen 

refueling than are flown to. The reason is the strict safety 

requirements in commercial aviation, where alternate airports 

must be designated for each route. An example of this 

comes from Scotland's Loganair, which serves much of the 

UK's regional routes and is one of the busiest airlines when 

it comes to testing new technologies. Loganair serves numerous 

routes such as the "island hopping" Orkney routes, 

which in terms of sheer flying distance would be ideal for 

all-electric regional jets. These are expected to go into production 

ahead of the H 2 

models. But the alternate airport for 

the Orkney capital of Kirkwall is Aberdeen, more than 200 

kilometers away – and thus out of range for all-electric flying 

in the foreseeable future. So if an infrastructure dilemma in 

hydrogen operations is to be avoided, implementation and 

operation must be straightforward and economical, not only 

for airlines but also for airports.

AIRBUS 

“WE SET OURSELVES 

UP FOR A GREAT 

CHALLENGE” 

54 

ZEROe Fuel Cell Engine Model. 

Find out more 

about the Airbus 

Summit here. 

When announcing our ambition to develop 

the world’s first ZEROe aircraft by 2035, we 

set ourselves up for a great challenge. To 

propel this aircraft, we are working on two 

ways of using hydrogen. First, via direct 

combustion in a gas turbine, and second, by 

using fuel cells to convert the hydrogen into 

electricity in order to power a propeller 

engine. To maintain a broad scope we are 

developing both options before finally determining 

which system will power our future 

aircraft. Regarding the fuel cell option, 

we revealed the development of a hydrogen-powered 

fuel cell engine at the Airbus 

Summit 2023. 

POWERING THE FUTURE OF AVIATION 

For this development, the fuel cells manufactured 

by our joint venture with ElringKlinger, 

Aerostack, are incorporated into a fuel cell system 

at the ZAL Techcenter in Hamburg. After design, 

assembly and testing in Hamburg, the fuel 

cell system is further tested in combination with 

the other components making up the propulsion 

system in our recently revealed E-Aircraft System 

Test House in Munich. 

Fuel cells are a potential solution to help us 

achieve our decarbonization ambition and we are 

focused on developing and testing this technology 

to understand whether it is feasible and viable 

for a 2035 entry-into-service of a ZEROe aircraft.

“WE SET OURSELVES UP FOR A GREAT CHALLENGE” 

Learn more about our 

zero emission journey. 

“Fuel cells are a potential solution 

to help us achieve our 

decarbonization ambition.” 

Glenn Llewellyn, VP Zero-Emission Aircraft, Airbus 

The technology will be tested on the A380 MSN1 

flight test aircraft for new hydrogen technologies 

toward the middle of the decade. The flight test 

aircraft for new hydrogen technologies is currently 

being modified to carry liquid hydrogen tanks 

and their associated distribution systems. 

PAVING THE WAY TO A HIGH-EFFICIENCY 

MULTI-MEGAWATT FUEL CELL SYSTEM 

One of the main difficulties in achieving this goal 

is to reach an electrical output high enough to 

provide enough energy for the electrical engines 

to power the aircraft. The first step to overcome 

this difficulty has been achieved in the last years 

by our development of fuel cell stacks and their 

combination in fuel cell systems. Based on this 

knowledge, we managed to design and develop 

the first fuel cell engine demonstrator on a labscale 

basis that reaches the megawatt class and 

comes closer to our ultimate goal. We enjoyed 

significant learnings that will help us develop future 

engines. By continuing to invest in this technology 

we are giving ourselves additional options 

that will inform our decisions on the architecture 

of our future ZEROe aircraft, the development of 

which we intend to launch in the 2027–2028 

timeframe. 

team is based in and around ZAL providing a 

significant impact towards the ambitious goal of 

a ZEROe aircraft. Airbus identified hydrogen as 

one of the most promising alternatives to power 

a ZEROe aircraft, because it emits no carbon dioxide 

when generated from renewable energy, 

with water being its most significant by-product. 

Hydrogen fuel cells, especially when stacked together, 

increase their power output allowing 

scalability. In addition, an engine powered by hydrogen 

fuel cells produces zero NOx emissions 

or contrails, thereby offering additional decarbonization 

benefits. 

55 

CONTRIBUTING TO THE AMBITION: 

RIGHT HERE, RIGHT NOW! 

Hauke Lüdders is the Head of the Fuel Cell propulsion 

systems development at Airbus. He is 

one of the early movers in Airbus, being enthusiastic 

about bringing sustainable energy sources, 

in particular fuel cells, on board Airbus commercial 

aircraft. Hauke and the majority of his 

CONTACT 

Hauke Lüdders 

hauke-peer.luedders@airbus.com 

johannes.hartmann@airbus.com

AIRBUS 

PIONEERING A 

CIRCULAR CARBON 

ECONOMY WITH 

DIRECT AIR CAPTURE 

56 

Delivery of the first 

DAC10 unit to the launch 

customer Jones Food 

Company in Bristol / UK 

in February 2023. Missing 

in the picture are 

our three dual students 

supporting the launch. 

In the long term, CO 2 

sourced from the air 

will play a key role in a net-zero emission 

economy, including as a carbon source for 

energy, fertilizers and chemicals. With the 

Airbus carbon capture technology that has 

been developed as the life support system 

for the ISS, we are able to capture CO 2 

from 

ambient air and turn it into a feedstock for 

valuable things “made from air.” At our venture 

we listen to commercial markets and 

engineer scalable carbon removal technologies 

that seamlessly integrate into existing 

hardware. 

PIONEERING A CIRCULAR 

CARBON ECO NOMY 

Direct Air Capture (DAC) could help to contribute 

to a sustainable circular carbon economy by 

capturing carbon dioxide (CO 2 

) directly from the 

atmosphere. The idea is that captured CO 2 

can

PIONEERING A CIRCULAR CARBON ECONOMY WITH DIRECT AIR CAPTURE 


DAC technology. 

come full circle, such that it could be used in the 

production of carbon-negative materials, power-to-liquid 

(P2L) eFuels, fertilizers, green carbon 

fibers, building materials, and more. In a 

nutshell, DAC could be offered as a service to 

companies that not only want to reduce their 

direct and indirect carbon footprint, but also 

“sink” CO 2 

from the atmosphere into sustainable 

practical applications. 

DERIVED FROM INTERNATIONAL SPACE 

STATION (ISS) LIFE SUPPORT SYSTEM 

The lightweight and compact DAC device – has 

been specially developed in-house and driven by 

Airbus Scale, bringing together teams from Airbus 

Commercial Aircraft and Airbus Defence and 

Space. One of the key advantages of the derived 

terrestrial DAC unit, being self-contained and only 

a few meters long, wide and high – about the 

size of a mobile burger stall – is that it can be 

brought on-site exactly to where the end customer 

may need the CO 2 

for various scenarios, 

such as those mentioned above. 

SUSTAINABILITY ADVANTAGES FOR THE 

VERTICAL FARMING INDUSTRY 

For the vertical farming / controlled environment 

agriculture industry in particular – which consumes 

about 200,000 tonnes of CO 2 

annually – 

DAC technology promises tantalizing benefits by 

supporting indoor plant growth and photosynthesis 

using CO 2 

taken from the surrounding air. 

Currently, the CO 2 

used by this industry is not 

only produced by burning propane gas (or some 

other fuel), but it is subsequently transported 

hundreds of kilometers over land or sea from 

where the CO 2 

was originally captured, all the 

way to the actual point of use – consuming even 

more energy with additional associated CO 2 

emissions. The potential scope for CO 2 

emissions 

reductions and overall energy – and cost – savings 

with the portable DAC innovation are therefore 

considerable. 

captured through an adsorption-based DAC, 

which splits the capturing process into two steps: 

firstly, a fan sucks in air which passes over a solid 

amine-based filter that selectively binds the 

CO 2 

. Airbus has patented a solid-amine resin, 

which efficiently captures CO 2 

even at low concentration 

levels. This phase continues until the 

amine resin is saturated with the greenhouse 

gas. In a second step, the filter is regenerated 

through the application of heat, which desorbs 

the CO 2 

into a pure stream and releases the 

treated air. This air can then be transferred and 

used for other applications.” 

MODULAR APPROACH FOR 

FUTURE GROWTH 

Antje Bulmann adds: “We already know from our 

various discovery calls with potential customers 

in the vertical farming sector, but also in other 

segments, that our current DAC size – capable of 

capturing around ten tonnes (about 5,000 cubic 

meters) of CO 2 

per year – might be suitable as a 

first step.” 

The modular DAC architecture will allow it to 

grow as future market needs require. The introductory 

“DAC10” proof-of-concept version will in 

future enable the stacking of multiple modules 

together to create a larger DAC – a proposed 

“DAC100” – which will still be easy to transport 

and have an estimated CO 2 

capture capacity approaching 

100 tonnes per year. Looking even 

further ahead, a 1,000-tonne “DAC1000” version 

is even being suggested. 

So what does all this mean for the average person? 

Antje Bulmann is optimistic when it comes 

to the future: “One day you’ll be able to take an 

eFuel-powered carbon-neutral flight across the 

Atlantic in a plane with materials partly made 

from CO 2 

, carrying and wearing items that are 

made from CO 2 

and eating fresh salads fertilized 

with CO 2 

from the air!” 

57 

MODUS OPERANDI … 

So how does technology actually work? Antje Bulmann, 

permanent Airbus Scale team member 

and leader of the project, explains: “The CO 2 

is 

CONTACT 

Antje Bulmann 

antje.bulmann@airbus.com


58 

FROM 30 MINUTES 

TO 10 HOURS’ 

FLIGHT TIME 



ZAL GmbH quadrupled the flight time of its 

drone by converting the battery operation 

to pressure-stored hydrogen in combination 

with a fuel cell. Thus, the flight time increased 

from 30 minutes to over two hours. 

However, this is only a fraction of what is 

possible with liquid hydrogen (LH 2 

). 

A project called LiquiDrone* is currently testing 

the conversion of a drone to liquid hydrogen. 

12 liters of liquid hydrogen (the equivalent of 

about 850 grams) are to be stored safely at a 

temperature of -253 °C for the duration of the 

mission and made available for electric drone 

propulsion via a fuel cell. The focus of ZAL GmbH 

is the provision of the test platform “ZALbatros,” 

an Unmanned Aircraft System (UAS) already 

tested with a compressed hydrogen tank, as well 

as the development of an energy management 

system for the optimized use of the tank contents. 

ZAL GmbH will continue to handle the liquid 

hydrogen, the overall integration, and the 

execution of the system tests. If the project is a 

success, the research partners expect the flight 

time to be extended to more than ten hours. 

* The LiquiDrone project is funded by the German Federal Ministry of Digital Affairs and Transport (BMDV). The four research partners 

(RST Rostock-System Technik GmbH, BaltiCo GmbH, University of Rostock – Chair of Engineering Mechanics / Dynamics, and ZAL 

GmbH) started their research in June 2022.

LIQUIDRONE & WINGCOPTER 

CONTACT 

Dr. Christoph Hess 

christoph.hess@zal.aero 

Sample model of a tank for liquid hydrogen. 

59 


ZALbatros. 

HYDROGEN 

POWER FOR 

DELIVERY DRONE 

Watch Wing copter 198 

here, the world‘s 

first triple-drop delivery 

drone. 

The vision of using delivery drones to improve or 

even save lives is both widely known and challenging. 

One company that has succeeded in making this happen 

is Wingcopter. With its same-named drone, the 

company has proven that it can successfully deliver 

medical supplies to regions that are geographically 

hard to reach. The delivery drones feature flight efficiency 

and high re silience. 

In the future, the plan is for the battery-powered 

drones to also take off on green hydrogen, making 

them not only emission-free but also even more powerful 

in range. The wingcopter‘s conversion to hydrogen 

will take place at ZAL TechCenter. As part of a 

development partnership with ZAL GmbH, a solution 

is being developed that will fit into the existing technical 

ecosystem of the delivery drone.

LUFTHANSA TECHNIK 

PREPARING 

FOR THE FUTURE 

60 

A decommissioned Lufthansa Group A320 is to become Hamburg’s Hydrogen Aviation Lab. 

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 focus es on 

maintenance and ground opera tions of hydrogen 

use cases in commercial aviation. 

The currently planned range of components to 

be installed into the Hydrogen Aviation Lab encompasses 

an internal cryo-tank for liquid hydrogen 

(LH 2 

), a fuel cell system, a condition ing 

system and a broad variety of pipes and interfac- 

es between the various installations. Lufthansa 

Technik personnel will carry out the majority of 

these installations into the used Airbus A320, 

here and there supported by employees of the 

other project partners. 

In addition, the Hydrogen Aviation Lab will also 

encompass ground infrastructure, for example 

an external LH 2 

refueling unit. A main challenge 

of the project is to find suitable commercial offthe-shelf 

solutions to be used, as most LH 2 

hardware 

is designed for industrial processes with 

high demand. If, in the future, other types of

HYDROGEN AVIATION LAB 

“We want to be ready for 

hydrogen ground operations 

in aviation.” 

Gerrit Rexhausen, Lufthansa Technik, Project Lead Hydrogen Aviation Lab 

components become the focus of research, 

Lufthansa Technik can retrofit them into the aircraft 

as well. 

Moreover, it is important to note that the 

Hydrogen Aviation Lab will not only consist 

of the physical aircraft, but also of its digital 

twin. Led by DLR, all afore-mentioned LH2 installations 

will also be modeled digitally in order to 

investigate forms of digital health monitoring 

and predictive MRO that can subsequently be 

validated with the physical project setup. 

To highlight its new role as a scientific field laboratory, 

the A320 has been adorned with an entirely new livery. To 

foliate the aircraft skin, Lufthansa Technik used around 

950 square meters of foil, and it took two weeks of work 

to complete. 

61 

In general, the project plan is to investigate aspects 

such as time-efficient refueling with liq uid 

hydrogen, safe and efficient repair of the relevant 

components, and how to deal with the relevant 

components as well as with incidents. In 

doing so, the project will not only prepare the 

partners for this promising future technology 

early on, it is also eager to deliver interesting impulses 

for aircraft, engine or component OEMs 

and their future designs for hydrogen-powered 

aircraft. Thus, the Hydrogen Aviation Lab will 

evolve into a platform for various follow-on research 

projects regarding the use of hydrogen in 

commercial aviation. 

Complex puzzle: one main work package is the integration 

of the hydrogen components and their interconnection. 

In the cargo compartment, for example, the 

researchers have to define special space budgets for the 

hydrogen piping and other connection lines, such as for 

the power electronics. 

Additional challenges to be investigated in the 

Lab focus on cooling and insulation, boil-off, inertization 

and staff training. Those aspects, with 

today’s knowledge, will pose great challenges not 

only for MROs, but for anyone who has to deal 

with this future aircraft technology on the 

ground. All of them bring up new questions and 

challenges the industry needs to address. 

Concept for the Liquid Hydrogen Refueling Unit. 

CONTACT 

Gerrit Rexhausen 

gerrit.rexhausen@lht.dlh.de

DLR 

DOUBLING DOWN 

ON RESEARCH: 

THE HYDROGEN 

AVIATION LAB AND 

ITS DIGITAL TWIN 

62 

The German Aerospace Center (DLR) is using 

the Hydrogen Aviation Lab’s unique environment 

to research hydrogen system designs 

and assess future operational challenges. 

INTEGRATING THE HYDROGEN SYSTEM 

INTO THE AIRCRAFT 

In order to ensure the full functionality of the 

A320 Hydrogen Lab, DLR supports with the design 

and engineering of the on-board hydrogen 

storage system. Due to the higher density, the 

hydrogen is stored in the liquid phase (LH 2 

). A 

small LH 2 

tank with about 200 l capacity is used 

to supply the fuel cell with hydrogen. After draining 

LH 2 

from the tank, it is evaporated and heated 

to ambient temperatures using an electrical 

evaporator. Afterwards the gaseous hydrogen 

(GH 2 

) is routed to the fuel cell. To allow the filling 

and draining of the LH 2 

tank and secondary functions 

like pressurization of the tank and to enable 

conditioning of the system before and after 

the test, an armature panel is used. Due to last 

year’s investigation of the A320 structure, the 

tank, evaporator and panel are installed in the 

rear part of the passenger cabin of the A320. 

A fuel cell will replace 

the APU in the rear of aircraft. 

In addition to setting up the A320 laboratory, 

DLR is also pressing ahead with the development 

of the digital platform, which represents the digital 

twin. Here, data and the hydrogen system 

parameters flow together and can be analyzed 

by the expert teams. This includes, for example, 

analyzing the installation spaces for system integration, 

evaluating sensor data and identifying 

the interactions of the new hydrogen systems 

with the board systems of the A320. The advantage 

of this virtual environment is a simple and 

fast extension of the hydrogen infrastructure 

and the analysis of further aspects from operation, 

maintenance, and design. First data and 

models of the A320 were already integrated into 

this virtual en vironment last year.

HYDROGEN AVIATION LAB 

IN ADDITION TO SETTING UP THE A320 LABO- 

RATORY, DLR IS ALSO PRESSING AHEAD WITH 

THE DEVELOPMENT OF THE DIGITAL PLATFORM, 

WHICH REPRESENTS THE DIGITAL TWIN. HERE, 

DATA AND THE HYDROGEN SYSTEM PARAMETERS 

FLOW TOGETHER AND CAN BE ANALYZED BY 

THE EXPERT TEAMS. 

ENGINEERING THE FUEL CELL SYSTEM 

DLR’s Institute of Engineering Thermodynamics 

is developing the fuel cell system for the Hydrogen 

Aviation Lab, which will replace the original 

auxiliary power unit (APU) of the A320 in its functions 

and duties. For this purpose, the APU of the 

A320 was completely removed to clear the space 

for the integration of the fuel cell system. The 

main requirement is to use existing airframe and 

aircraft interfaces for mechanical integration and 

for supplying the fuel cell system with hydrogen 

and atmospheric oxygen. In addition, the electrical 

energy generated by the fuel cell system has 

to be fed into the A320’s distribution network. 

Together with the DLR Institute of System Architectures 

in Aeronautics, the DLR has reverse engineered 

the APU compartment of the A320 to 

provide information about dimensions and to 

generate a CAD model for the design layout of 

the fuel cell system and its integration. 

Researchers at the DLR Institute of Engineering 

Thermodynamics are simulating and experimentally 

validating effects on system design, working 

points, and operation procedures of the fuel cell 

system in an aircraft environment, to identify robust 

operation procedures using liquid hydrogen 

as a fuel. 

INVESTIGATING MAINTENANCE 

CHALLENGES 

When designing new systems, it is essential that 

the maintenance effort is already taken into account 

during the design phase. But how does 

one estimate the maintenance requirements of 

hydrogen systems that do not yet exist? Researchers 

at the DLR Institute of Maintenance, 

Repair and Overhaul, in cooperation with 

Digital twin in virtual reality. 

Lufthansa Technik, ZAL GmbH, and other DLR 

institutes, have developed an elaborate modeling 

of a large number of components of the hydrogen 

system architecture, which is being designed 

in the Hydrogen Aviation Lab. This is 

probably the most detailed analysis of these 

new systems to date. It enables the estimation 

of maintenance tasks and efforts, intervals, and 

cost increases associated with the maintenance 

of hydrogen systems. The model is easily scalable 

if specific parameters are defined for H2 

systems in the future. 

The institute is also exploiting the possibilities of 

the Hydrogen Aviation Lab’s realistic environment 

in other projects. One is dedicated to the 

detection of hydrogen leakages, which represent 

a serious safety risk. With a widely ramified sensor 

network, the goal is to localize even small 

leakages. Another focus of the research is on potential 

applications of extended reality applications. 

In this way, it would become possible to 

visualize sensor network data even in difficult 

working environments, making work for maintenance 

staff safer and more efficient. 

CONTACT 

Dr. Jörn Biedermann 

joern.biedermann@dlr.de 

63

TECCON 

64 

ENVIRON MENTALLY 

FRIENDLY INTO 

THE FUTURE 

High-performance, scalable hydrogen power 

trains are necessary for low-carbon propulsion 

of aircraft. Developing these systems 

for fixed-wing UAVs and small 

airplanes is the goal of the joint research 

project H2-FINITY. The ensuing combination 

of hydrogen tank, fuel cell, and electric motor 

is putting into practice on a small scale 

what will possibly be the future of commercial 

aviation. 

MOTIVATION 

Aviation is at a turning point. Environmental and 

economical requirements demand new technologies, 

products, and services that support the 

goals of sustainability and cli mate neutrality. One 

key component is the use of hydrogen as an energy 

source. Examples for existing efforts to de- 

velop hydrogen solutions for the air transportation 

sector range from clean aviation at the 

European level to the Hydrogen Aviation Lab 

recently established in Hamburg. But large aircraft 

also bring large problems that require 

equivalent efforts and time frames. 

H2-FINITY has been designed to address a different 

question: how can small and medium-sized 

enterprises (SMEs) contribute to technological 

progress and create a future-oriented product 

that uses hydrogen as its primary source of energy 

to address the market of small aerial vehicles? 

Here, the systems are not as complex, the 

design space is not as limited, and regulations 

are not as strict as in commercial aviation. The 

task is the development of a scalable power train 

for small aerial vehicles with a take-off mass between 

25 kg and 250 kg. This does not only in-

ENVIRON MENTALLY FRIENDLY INTO THE FUTURE 

HIGH-PERFORMANCE, SCALABLE HYDROGEN 

POWER TRAINS ARE NECESSARY FOR LOW-CARBON 

PROPULSION OF AIRCRAFT. 

Visit the H2-FINITY 

website here. 

clude most civil unmanned flight vehicles – a 

market sector that is expected to see an enormous 

boost in the coming years – but also the 

new 120 kg-class of manned aircraft. 

INNOVATION 

The power requirements for commercial aircraft 

are still outside the range of today’s fuel cell 

technology, whereas smaller H2 fuel cells are already 

available with promising performance and 

at reasonable costs. Thus, these systems are 

suitable for unmanned aerial vehicles (UAVs), also 

known as drones. 

H2-FINITY has been designed to address the 

main challenge of a hybrid electric power train 

for small aircraft: combining cutting- edge components 

to a mature, scalable propulsion system 

that can be used in real-world applications. 

What sounds rather mundane in theory proves 

to be a challenging under taking: understanding 

the interactions between the components, optimizing 

the overall system, integrating it into the 

vehicle, ensuring reliable operation under various 

conditions, safe handling of gaseous or liquid 

hydrogen, certification aspects and solving 

practical problems like refueling and maintenance. 

To optimize performance and automate 

operations, the UAVs developed within H2- 

FINITY will take off from and land on a mobile 

runway system. 

Meeting at ZAL: the team works on integrating power train 

com ponents into a test vehicle. 

THE TAKE-AWAY 

H2-FINITY demonstrates that even small companies 

can team up and innovate together. The 

project can also be seen as a blueprint that joint 

research allows SMEs to step out of the role of 

low-tier suppliers and to acquire system competence 

of their own. Last not least, it shows that 

there are still exciting possibilities for young professionals 

to shape challenging, future-oriented 

innovation and technology in aviation. 

ACKNOWLEDGEMENTS 

H2-FINITY is part of the initiative GATE (Green 

Aviation Technologies). The project is support ed 

by funds of the city of Hamburg and administered 

by IFB Hamburg. 

CONTACT 

Jörg Manthey 

joerg.manthey@teccon.de 

65 

The mobile runway 

system for fully automated 

drone launch, 

landing and turnaround.


WE EMPOWER 

FUTURE TECH 

TALENTS 

66 

At the proTechnicale School Winter Camp in February 2023, participants met their mentors 

Susanne von Arciszewski (left) and Anna Matzat (right). 

Since 2010, the non-profit SOPHIA.T gGmbH 

has been empowering young wom en with 

innovative tech education programs, namely 

proTechnicale Classic, a gap year for female 

high school gradu ates and proTechnicale 

School, a digital program for female 

students attending high school. Since 2016, 

the home base of proTechnicale is the ZAL 

TechCenter. A perfect place to connect, inspire, 

and empower young talents. “The fact 

that proTechnicale is located at the ZAL 

TechCenter is a ‘win-win-win’ situation,” 

confirms Roland Gerhards, CEO of ZAL GmbH, 

“for the proTechnicale participants, the 

local companies and ZAL GmbH itself.” pro- 

Technicale is funded primarily by the Hamburg 

Ministry of Economics and Innovation, 

but also by foundations, companies, and 

private individuals throughout Germany. 

proTechnicale School and Classic aim to attract 

more women to studies and professions related 

to STEM (science, technology, engineering, 

mathematics). Over 90 percent of the graduates 

of proTechnicale Classic to date have chosen 

STEM-related studies as a result of the program. 

The uniqueness of the concept is based 

on the combination of the transfer of technical

PROTECHNICALE – WE EMPOWER FUTURE TECH TALENTS 

PROTECHNICALE SCHOOL IS AIMED AT HIGH 

SCHOOL GIRLS FROM ALL OVER GERMANY OR 

FROM SIMILAR TIME ZONES. 

know ledge and practical experience. On top of 

that, there is a strong focus on personal development, 

such as boosting self-confidence as well 

as reflecting on one’s own personal strengths and 

goals. “The founder of proTechnicale, Manfred 

Kennel, decided to include personal development 

workshops and philosophy,” explains Friederike 

Fechner, managing director of SOPHIA.T gGmbH 

and project manager of proTechnicale. Thus, the 

opportunities and relevance for the future job 

market were recognized early on. “In our experience, 

young women have all the important future 

skills that are needed for STEM studies, but the 

variety of choices can be overwhelming and in 

most cases, young women lack STEM-role models 

with whom they can identify. That is where we 

come in with proTechnicale and make our contribution.” 

TWO PROGRAMS – ONE GOAL 

Learning – and at proTechnicale Classic also 

living – in a safe space are important components. 

Moreover, proTechnicale places a strong 

emphasis on interpersonal exchange – in mentoring 

programs as well as in networking sessions 

with women from the STEM world. Although the 

number of Classic participants is limited to a 

maximum of 15 proTechnicalees, the launch of 

the digital proTechnicale School program in 2022 

now allows adding 30 to 40 more young women 

each year. Both programs have already won various 

awards, most recently the “Hidden Movers 

Award” 2022 from the Deloitte Foundation. 

PROTECHNICALE CLASSIC – TECH ORIENTA- 

TION GAP YEAR 

proTechnicale Classic is a gap year after high 

school focusing on study orientation highlighting 

the areas of aerospace, renewables, programming, 

and personality development. The 

program starts annually on October 1 in Hamburg. 

The number of participants is limited to 

15 female high school graduates from Germany 

and around the world. During the gap year, the 

proTechnicalees live together in project-owned 

shared apartments in Hamburg. Most of the 

classes take place at the ZAL TechCenter. In addition, 

they visit several universities and get a 

taste of corporate life during internships in Germany 

and abroad, while strengthening their personalities. 

The participants lay the foundation 

for their professional network during company 

speed datings at ZAL TechCenter, on field trips, 

and during fireside chats with female STEM role 

models. Peer mentoring rounds off the program, 

pairing a current participant with an alumna. 

PROTECHNICALE SCHOOL – DIGITAL STUDY 

ORIENTATION 

proTechnicale School is aimed at female high 

school students from all over Germany or from 

similar time zones. The participants are enthusiastic 

about STEM topics, motivated to develop 

their skills, and exchange ideas with like-minded 

people. Up to 20 young women can participate 

in the digital program where they meet regularly 

once a week plus one saturday a month. There 

are two runs each year, starting on March 1 and 

September 1. For a total of five months, they take 

part in various courses covering aerospace, renewables, 

personal development, and networking. 

In addition, they are in close contact with 

many STEM role models and entrepreneurs. 

Their curriculum also includes programming, social 

entrepreneurship, and a mentoring module. 

PROTECHNICALE CAREERS 

After proTechnicale, the graduates take 

different paths; they study mechanical engineering, 

aerospace engineering, biotechnol ogy, 

or physics, they found their own companies, or 

train to become pilots. “By empowering, inspiring, 

and connecting female STEM talents, our 

programs make an important contribution,” explains 

Friederike Fechner. 

Learn more about 

proTechnicale here. 

CONTACT 

proTechnicale Team 

office@protechnicale.de 

67

SIEMENS 

“WE ARE READY 

TO SHAPE THE 

FUTURE” 

68 

Find out more about 

Siemens Aerospace. 

Siemens and ZAL have established a 

long-lasting strategic partnership over several 

years to collaborate on cutting-edge research 

and development projects in the 

aerospace industry. Together, we are working 

on projects related to sustainable aviation, 

including the development of advanced 

materials, aerodynamics, and 

propulsion systems, as well as improving 

energy efficiency and reducing noise pollution. 

Our partnership represents a significant 

step forward in advancing aerospace 

technology and highlights the importance 

of collaboration between industry and research 

institutions. 

only to create a virtual exhibition of our holistic 

Siemens approach but also a virtual meeting 

room for customers and our aerospace colleagues. 

CHALLENGES THAT WE’VE FACED 

Siemens has been an expert in automation for 

many years and supports customers on their 

way to digital excellence with a focus on sustainability 

and innovation. We offer solutions for the 

specific requirements of the aerospace industry. 

New planes will be lighter, faster, and more efficient. 

These aircraft of the future place new demands 

on product design, production planning, 

engineering, and execution, as well as service. 

At the very beginning, it was just a small idea: 

aerospace in your pocket. Our intention was not 

HISTORY OF ORIGINS 

So one of our first steps was to specify and de-

“WE ARE READY TO SHAPE THE FUTURE” 

AEROSPACE IN YOUR POCKET – WELCOME 

TO OUR NEW DIGITAL WORLD – AEROWORLD. 

Take a look at 

AEROWORLD. 

velop all design, manufacturing and control ling 

stations according to an aircraft lifecycle, including 

the machine builder’s interests. 

AIRCRAFT DESIGN 

Fly it before you build it. In our software room, 

we show our customers how the aerospace industry 

can benefit from digitalization. With intelligent 

tools for product design, production planning 

and execution as well as seamless 

communication between all systems. 

Here, they can discover how to benefit from 

merging the virtual and the real world and see 

the possibilities provided by the digital twins of 

product, machine, plant, and the entire production. 

The virtual version of an airplane represents 

every detail and can be used to sim ulate, test 

and optimize the airplane before production 

even starts. 

PART MANUFACTURING 

The first station in our manufacturing hall is the 

SINUMILL, a digital twin of a real milling machine 

equipped with best-in-class automation products. 

There, we can for example demonstrate 

high-end part manufacturing with SINUMERIK 

ONE, our digital native CNC. Our customers can 

experience how Siemens is able to support the 

process of maximizing productivity, to innovate 

faster, be on the leading edge of digitalization, 

and unleash a new way of thinking. 

ADDITIVE MANUFACTURING 

Additive manufacturing is perfect for aerospace. 

Freedom of design prevails, the parts are light, 

and printing spare parts is easy. So our AERO- 

WORLD includes this cutting-edge technology, of 

course. And best of all, you can walk through our 

digital AMEC straight from the AEROWORLD 

Showroom. 

CNC ROBOTICS 

Robots can be used not only for drilling and milling 

technologies, but also for additive manufacturing 

applications – highest path accuracy, flexibility 

and mobility are guaranteed. 

ASSEMBLY 

Best-in-class solutions for composites manufacturing, 

pre-assembly and final assembly processes, 

including automated guided vehicles and 

cranes – our controllers ensure maximum efficiency 

for high-end applications in machine and 

system automation. Motion control is our expertise. 

Aerospace manufacturers benefit from a 

high degree of flexibility, convenient engineering, 

and rapid commissioning. 

ENGINE MANUFACTURING 

At this station we demonstrate to our custom ers 

how we optimize engine production and shape 

accuracy and surface quality. We are experts in 

high-end grinding, milling, and turning technologies 

used to manufacture engine components in 

the most efficient way. 

DIGITAL CONNECTIVITY AND POWER 

Our customers can benefit from our unique expertise 

in industrial communication and networking. 

Our industrial communication portfolio 

permits the optimal networking of automation 

components based on professional infrastructure 

planning and implementation. 

CONTROL ROOM 

This is where best-in-class solutions, for smart 

infrastructure, industrial services and cloud 

technologies take place. Manufacturing operations 

management (MOM) is a holistic solution 

that provides full visibility into manufacturing 

processes to steadily improve manufacturing operations 

performance. MOM consolidates all 

production processes to improve quality management, 

advanced planning and scheduling, 

manufacturing execution systems, R&D management, 

and more. 

ADVANTAGES 

We take our customers on a journey, a tour 

through a virtual aerospace manufacturing hall, 

where we prove our know-how each and every 

single step of the way. 

CONTACT 

Kevin Badenhoop-Clausen 

kevin.badenhoop-clausen@ 

siemens.com 

69


70 

THE EXECUTIVE 

BOARD 

NOW WITH FOUR 

CHAIRMEN 

IN THE ZAL E. V. 

ZAL e. V. bundles the interests of mediumsized 

and smaller companies within the 

shareholder structure of ZAL and offers 

them opportunities to influence decisionmaking 

processes on an equal footing with 

the major shareholders such as Airbus Operations 

GmbH and Lufthansa Technik AG. 

Our member companies are innovative partners 

for the development and industrialization 

of future aviation technologies, thus making an 

important contribution to strengthening the 

world’s third largest location for civil aviation. 

As a shareholder, we actively support the current 

strategy and orientation of ZAL and are 

pleased about the ZAL TechCenter’s expansion. 

Modern new work concepts and the greatest 

possible flexibility in technical equipment are 

essential for successful project- based research 

work. 

In June 2022, the new extended board was elected 

at the annual general meeting. The concrete 

implementation of the association’s organizational 

possibilities is tied to the two positions of 

the first and second chairmen of the executive 

board. Jörg Manthey, first chairman in his function 

as delegate of HECAS e. V., represents the 

voice of the association in the quarterly meetings 

of the ZAL supervisory board. Thorsten Reimetz, 

second chairman in his function as an exemplary 

supplier, represents the association at the ZAL 

shareholders’ meeting, which takes place once 

a year. The third person, Sebastian Corth, represents 

the interests of the board in his function 

as a board member of Hanse Aerospace e. V. 

Currently, the chairmen are focusing particularly 

on topics related to digitalization and hydrogen 

applications. And Dr. Martin Spieck from the 

company Thelsys GmbH, which is also a member 

of the ZAV e. V., focuses on research and innovation 

in joint R&D projects.

ZAL E. V. – EXECUTIVE BOARD NOW WITH FOUR CHAIRMEN 

CONTACT 

Jörg Manthey 

joerg.manthey@teccon.de 

71 

ZAL e. V. board from left to right side: 

Sebastian Corth, Thorsten Reimetz, 

Jörg Manthey, and Dr. Martin Spieck. 

ZAL ASSOCIATION MEMBERS 

AERTEC SOLUTIONS GMBH 

ALTEN TECHNOLOGY GMBH 

ALTRAN DEUTSCHLAND S. A. S. & CO. KG 

CLUSTER ERNEUERBARER ENERGIEN 

HAMBURG E. V. 

CTC GMBH STADE 

DASSAULT SYSTÈMES DEUTSCHLAND GMBH 

DIEHL AVIATION LAUPHEIM GMBH 

FLUGHAFEN HAMBURG GMBH 

HANDELSKAMMER HAMBURG 

HANSE-AEROSPACE E. V. 

HECAS E. V. 

HONEYWELL INTERNATIONAL S. R. O. 

INDUSTRIEANLAGEN-BETRIEBSGESELLSCHAFT MBH 

LATÉSYS GMBH 

SAFRAN ENGINEERING SERVICES GMBH 

SFS GROUP GERMANY GMBH 

SILVER ATENA 

TESA SE 

THE AIRCRAFT PERFORMANCE 

COMPANY GMBH 

THELSYS GMBH


Roland Gerhards, 

CEO ZAL GmbH, welcomes 

the participants. 

72 

MAKING 

CHANGE 

HAPPEN 

We invited key players in aviation to talk 

about Change. And they did: Airbus, Boeing, 

H3 Dynamics, Loganair, and Lufthansa 

CleanTech Hub. They all joined ZAL Innovation 

Day 2022 to discuss how to navigate 

through turbulent times. 

Since 2017, the flagship event of ZAL has combined 

impulses from aviation research with 

networking. The program usually consists of 

workshops, live demos, ZAL tours, as well as researchers 

and futurists who come up with gripping 

talks on stage. 

In case you missed the event or simply want to 

recall the key findings, here’s your chance. Our 

recording of the presentations gives you insights 

into the exciting topics covered at the last event: 

global players’ approaches to sustainable aviation, 

the green aviation that is already happening, 

the development of new technologies, and 

the impact of start-ups driv ing change. 

Also, don’t miss what futurist Dixon has to say. 

He reveals the pitfalls you can avoid when forecasting 

the future. And it’s not just the content 

of his presentation that’s interesting, but also the 

way he delivers it. Due to an injured ankle, the 

Brit was unable to travel to the event and joined 

on a separate screen – life-size and in real-time 

communication with the host and audience. 

Watch the short film 

of the last event. 

Next year you can also expect a comprehensive 

program. You are welcome to register at event@zal.aero 

to make sure you don’t miss any news.

ZAL INNOVATION DAY – MAKING CHANGE HAPPEN 

“All of the stakeholders 

need to have like this 

set of cojones and they 

need to go.” 

Erin Beilharz, Managing Director CleanTech Hub at Lufthansa Group 

The presentation 

in full length. 

The Lufthansa Group has a great deal of know-how in the aviation 

industry. But one company alone – however large it may be – cannot 

bring about the change we need. Erin emphasizes how important 

it is for start-ups, governments, investors, and the aviation industry 

to work in concert. Her creed: success depends on the combined 

am bition of all. One current example is the Hydrogen Aviation Lab. 

73 

“I want to address 

some confusion: 

it’s definitely 2035!” 

Glenn Llewellyn, Vice President Zero Emission Aircraft at Airbus 

Glenn explains Airbus’ ambitious plan to bring a zero-emission 

aircraft to the commercial market. This requires a lot of research 

and development. An A380 serves as a test platform. The big 

advantage is that the model’s size means it can tolerate major 

modifications, such as a fifth engine for hydrogen testing. 


in full length.


“It’s a team sport. 

There is not one 

single solution.” 

Dr. Michael Haidinger, President Boeing Germany, 

Benelux, Central & Eastern Europe 



Boeing follows four strategies for decarbonizing aviation by 

2050. Fleet renewal, operational efficiency, renewable energy, 

and advanced technology. According to Michael, his company 

believes in SAF, especially concerning long-haul flights. Thus, 

by 2030 all aircraft are supposed to be compatible with SAF. 

The shorter the distance, the more electrification and hydrogen 

scenarios are going to take place. 

74 

“Policy can be 

driven by emotion.” 

Andy Smith, Head of Sustainability Strategy at Loganair Ltd. 

The Scottish airline Loganair is the UK’s largest regional airline, with 

35 destinations. The airline has shown in the past that it can act profitably 

even in challenging enviroments (remarkably, they operate the world’s 

shortest flight route with a duration of approx. 80 seconds). With the 2021 

Green Skies initiative, Loganair set itself the goal of having its operations 

carbon neutral by 2040. Speaker Andy Smith shares his experiences on how 

sus tainable practices can be implemented in aviation. 


in full length.

ZAL INNOVATION DAY – MAKING CHANGE HAPPEN 

“The world can change 

faster than you can 

hold a board meeting.” 

Dr. Patrick Dixon, Chairman of Global Change Ltd., author & Europe’s leading Futurist 



According to Patrick, the future is all about timing. The best strategy 

on earth does not work when it’s five years too early or too late. 

However, events can crush strategies. Thus, we must admit to ourselves 

that the future is not determined by innovation but by events triggering 

them. The Covid pandemic proved, for example, that the pharma industry 

can innovate four times faster than usual, if needs be. As for how this 

translates to aviation, Patrick offers several answers, one of which is 

that to accelerate change in aviation, we cannot work virtually. 

75 

“We designed 

down to get into 

the air faster.” 

Taras Wankewycz, Founder & CEO of H3 Dynamics 

Taras and his company H3 Dynamics are on a mission to decarbonize air mo bility. 

Their approach is to solve big technical and regulatory challenges with smallscale 

systems first, before facing the final goal of crewed hydrogen aviation. This 

“Darwinian” method has the advantage that each intermediate step also yields 

a usable product. Like their fully autonomous drone-in-a-box platform or their 

hydrogen propulsor nacelle. 


in full length.

IMPRINT 

ZAL CENTER OF APPLIED 

AERONAUTICAL RESEARCH 

Hein-Sass-Weg 22 

21129 Hamburg, Germany 

+49 40 248 595 0 

info@zael.aero 

zal.aero 

linkedin.com/company/zaltechcenter 

twitter.com/ZALTechCenter 

facebook.com/ZALTechCenter 

76 

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: Georg Wodarz; p. 6–7: Anne de Wolff, Claudia Höhne (2), Daniel Reinhardt, Noun Project (Colourcreatype, 

IYIKON, Mira iconic, Vectors Market); p. 8–9: Daniel Reinhardt (2); p. 10–11: Daniel Reinhardt (2), Airbus SAS 2023; 

p. 12–13: Lufthansa Technik AG (2), Christian-Albrechts-University, Kiel; p. 14–15: Daniel Reinhardt (2), Frankfurt Airport; p. 16: 

Adobe Stock (Sashkin); p. 18–19: Daniel Reinhardt (2), ZAL GmbH; p. 20: ZAL GmbH; p. 22: Trilux C. Meinschäfer; p. 23: Daniel 

Reinhardt (3); p. 24–25: Daniel Reinhardt (4), Sustainable Aero Lab; p. 26–27: DLR; p. 28: DLR (2), Daniel Reinhardt; p. 31: Dassault 

Systèmes, DLR-FOTOMEDIEN; p. 32–33: Daniel Reinhardt (3); p. 34–35: Shutterstock (Alraun), illustrated modules: FORM- 

BA (Evgenij Plekan); p. 36: AES; p. 38: Daniel Reinhardt; p. 37: Oliver Sorg, Sustainable Aero Lab; p. 40: Daniel Reinhardt; p. 42: 

Airbus; p. 43: 3D.aero; p. 44: Airbus; p. 45: Fraunhofer IFAM (2); p. 46–47: Daniel Reinhardt (2); p. 48: IDS Hamburg; p. 50 illustration: 

FORMBA (Ines Thaller); p. 52–53 illustration: ZAL GmbH; p. 54: Hervé GOUSSE – Master Films; p. 55: Airbus SAS 2022; 

p. 56: Airbus SAS 2023; p. 58: Daniel Reinhardt (2), WINGCOPTER; p. 60: Lufthansa Technik; p. 61 portrait: Jan Brandes, furthermore: 

Lufthansa Technik, LHT media base, ZAL GmbH; p. 62–63: DLR (2); p. 64–65: Teccon/Thelsys (2), mb+Partner; p. 66: 

proTechnicale; p. 68: Aeroworld; p. 71: Daniel Reinhardt; p. 72: Daniel Reinhardt; p. 73: Lufthansa, K. Bandic; p. 74: Christian 

Kruppa; p. 75: private 

THIS MAGAZINE WAS PRINTED IN A CLIMATE-NEUTRAL AND RESOURCE-SAVING WAY.

Tell us! Do you like the new magazine? 

And would you like your ZAL project to be 

included in it next time?

Future. Created in Hamburg.

FUTURED. ZAL Magazin 2023

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