Gemeinsam mit einem internationalen Konsortium realisieren wir regelmäßig Joint Partner Projekte zu verschiedenen Leichtbau-Forschungs- und Entwicklungsfragen. – Treiben Sie Ihre Entwicklung effizient voran!
Benchmarking Systems for high-gradient heating and hot particle blasting for fire testing of housing and functional materials for EV battery casings
Kick-off: July 15th 2025
Duration: approx. 9 months
Battery Casings for electrical vehicles, both for ground and air transportation, offer huge economical potential. All kinds of materials, steel, aluminum and composites are used to manufacture components of the battery casings. For all components, independent if used in the surrounding box/lid structure or as functional elements within the casing, the characterstic behaviour under thermal runaway conditions are essential criteria to test and to comply with legal and OEM-standards. AZL is renown for developing and operating test setups to provide evidence on the suitability of materials for application in battery casings.
What will you get?
Joint definition of test scenarios of relevance available at the market and expert assesment of testing results by implementation and comparison. Opportunity to co-define requirements for improving test procedures to further increase representativity for real thermal runaway events including testing results of your materials and comparison with other materials.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Development and benchmarking of design for-manufacturing-strategies to optimisematerial efficiency and cost
Kick-off: July 16th 2025
Duration: approx. 9 months
Hydrogen Pressure Vessels for mobile and stationary applications offer a huge economic potential for the composite value chain. Due to higher demands for material recyclability and advantages in production, a large interest in substituting thermoset by thermoplastic resins exists. A compensation of the higher material costs is only possible, when rethinking the design and manufacturing strategies. Processing options offered by thermoplastic composites can lead to new highly efficient designs and better utilization of these valuable materials, and by that reduce cost- and increase storage efficiency.
What will you get?
Expert assessment and evaluation of Design for Manufacturing Strategies for Pressure Vessels based on thermoplastic resins. Cylindrical and non-cylindrical designs will be coverd.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Market & Technology Study on Opportunities for Fiber-Reinforced Plastics in Space & Defense Applications
Kick-off: July 15th 2025
Duration: approx. 9 months
Applications in space- and defence technology are developing rapidly. Both technology fields are driven by constantly speeding up of innovation cycles and scaling of production volumes. Achieving technical requirements to produce components within these market segments is also crucial, so when composites can play out their specific advantages in terms of mechanical, protective, electrical, electromagnetical, chemical properties, the ability to cost-effectively manufacture integrated parts with complex shapes and capabilities, they can be positioned as the solution to go for at high margins.
What will you get?
Providing insights into market intelligence for well structured subsegments within the two markets, aerospace and defense, drivers in terms of technologies, insights into value chains, existing and future applications, providing technology trees with fact-sheets on systems and components, and analysing the specific opportunities for composites, we will provide you with a unique basis for your technology and business development strategies, all conducted by composite technology experts with a proven track record in market- and technology analysis.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
*bitte beachten Sie, dass alle Projektinformationen aufgrund der Internationalität der Projekte nur auf Englisch zur Verfügung stehen.
〉〉 Detaillierte, vorwettbewerbliche Untersuchung von Leichtbauwerkstoffen, -systemen oder -prozessen
〉〉 Verknüpfung von technischem Know-How und Marktwissen
〉〉 Kosteneffektives Budget basierend auf gemeinsamer Kostenteilung
〉〉 Kontakt zu einem breiten Netzwerk von industriellen Akteuren
Experimental Testing & Benchmarking | Thermoset and Thermoplastic Materials, Direct Winding & Press-Fit Technology
Duration: approx. 9 months
Kick-Off: November
Electric motors are playing an increasing role in automotive mobility, where efficiency is of highest importance. The same applies for many industrial and household applications. Composite rotor sleeves allow permanent magnet motors with high rotation speeds and very low Eddy current losses, leading to higher motor efficiencies over a wider operating range. The design optimisation, manufacturing and assembly processes for rotor sleeves were extensively studied in a previous AZL Joint Partner Project, showing high future potential of these components.
What you‘ll get:
You’ll gain detailed insights into various manufacturing processes and their optimization, including wet winding, towpreg winding, and thermoplastic tape winding, complemented by material quality evaluations. The results also cover different assembly methods, alternative layups, and prestress levels for press-fit and direct-wound configurations. Experimentally derived and validated data on carbon fibre composites provide a solid basis for understanding strength, stiffness, and failure behaviour, thereby increasing confidence in CAE predictions. In addition, quantified analyses of pre-stress levels, temperature limits, and wall-thickness effects deliver a deeper understanding of material performance. Finally, updated cost insights based on experimental data ensure a transparent view of materials and processes.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Global screening and use-case identification for saving costs and CO2 in large-scale production of highly cost driven injection moulding parts
Duration: approx. 7 months
Thermoplastic tapes offer excellent mechanical properties compared to short- or long-fiber reinforced thermoplastics (SGF, LGF). In particular, glass fiber tapes have already reached a cost level comparable to GF compounds. Carbon fiber tapes, however, still come with a significant cost premium—both compared to CF and especially to GF compounds. In addition to their established use in laminates, thermoplastic tapes can also be selectively integrated in small fractions into injection- and press-molded parts. It has been proven that local reinforcement with just a few percent of tapes leads to significant cost, weight, and CO2 footprint reduction all without requiring changes to existing production systems. Additionally, this technology supports the use of recycled materials, facilitating compliance with recycling regulations. Together with partners, AZL has developed an method to verify the application‘s suitability to foster the benefits of the technology.
What you‘ll get:
Insights into the quantified impact of local tape reinforcements on cost, weight and CO2 footprint for high volume applications manufactured today by injection- and press-moulding. Structural and non-structural applications across all industries, from home appliances to automotive. Usage in the context of design with recycling.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Proving and showcasing Eco-Design for and with recycling using thermoset and thermoplastic composite solutions
Duration: approx. 9 months
Battery casings for electric vehicles typically consist of a box structure and a lid. Both components require significant material use and must meet numerous demanding requirements. Thermoset and thermoplastic composite materials are particularly well-suited for these massproduced and high-value components. Regulations mandate that OEMs ensure the recyclability of battery casings and lids, including incorporating recycled materials. Due to their substantial size and weight, these components are well-suited for collection and reuse, making them an excellent source of postconsumer recyclates. Their size also enables innovative design and processing opportunities for integrating recycled materials locally. To maintain and reinforce the image of composite solutions as recyclable, it is crucial to effectively demonstrate the techniques and advantages to decision-makers in the automotive industry.
What you‘ll get:
AZL has a proven track record in designing composite-based, multi-material battery casings. Additionally, AZL offers extensive infrastructure for processing various composite materials, from small-scale coupons to full-scale component production. The project will specifically focus on demonstrating „Design for and with Recycling“ for thermoset and thermoplastic battery casings.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
*bitte beachten Sie, dass alle Projektinformationen aufgrund der Internationalität der Projekte nur auf Englisch zur Verfügung stehen.
Insights into emerging battery storage technologies and their impact on design factors for battery casings
Do you know…
What you‘ll get:
Expert assessment and evaluation of future battery technologies and their impact on requirements for material and design of battery casings.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Techniques for prediction of cell- and casing behaviour after the initial trigger event for thermal propagation
Do you know…
What you‘ll get:
The project provides know-how and predictive methods for the events happening after a first thermal runaway of a battery cell.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Potentials for composite materials and technologies in the energy transition market
Electric motors are playing an increasingly important role, especially for future mobility. High-speed permanent magnet motors offer several advantages, including high power density and efficiency.
Did you know?
What you‘ll get:
Expert assessment and evaluation of potentials for composite materials and technologies in the field of rotor sleeves for high-speed electric motors.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Potentials for composite materials and technologies in the field of air mobility and small/medium sized wind energy systems
Did you know?
What you‘ll get:
Expert assessment and evaluation of potentials for composite materials and technologies in the field of propellers and small to medium-sized rotors.
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services | AZL Aachen GmbH
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Kick-Off: November 14th, 2023
Key objectives:
What you‘ll get:
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services
Phone: +49 241 475 735 14
Mobile: +49 176 80488799
Email: philipp.froehlig@azl-aachen-gmbh.de
Workpackages:
If you are interested and would like to receive more information, please get in touch with:
Philipp Fröhlig
Head of Industrial Services
Phone: +49 241 475 735 14
Email: philipp.froehlig@azl-aachen-gmbh.de
Workpackages:
If you are interested and would like to receive more information, please get in touch with
Philipp Fröhlig
Head of Industrial Services
Phone: +49 241 475 735 14
Email: philipp.froehlig@azl-aachen-gmbh.de
*bitte beachten Sie, dass alle Projektinformationen aufgrund der Internationalität der Projekte nur auf Englisch zur Verfügung stehen.
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Expertise/ background in:
Production and development of composite parts
Materials: thermoset and thermoplastic resins, continuous fiber composites, metals and plastic-metal hybrids
Process: prepreg, autoclave, resin infusion, RTM, milling, tooling, joining, quality assurance
Design: CAD design and design to process
Networking: Matchmaking with academic and industrial partners
I will support you in:
