Together with an international consortium, we regularly realize Joint Partner Projects on different lightweight research and development questions. – Efficiently drive your development!
Joint Partner Projects
Upcoming Joint Partner Projects
Explore new industry-driven projects currently open for consortium formation
A 2026 Global Outlook on Growth, Sustainability, and Digitalization
Starting in Q3 of 2026
Duration: approx. 9 months
Building on the success of AZL’s landmark Buildings & Infrastructure study – conducted in 2017 with 32 global companies – this new initiative will reassess established applications and quantify emerging opportunities across markets, materials, and manufacturing technologies. The addressed market segments comprise following, among others: residential/non-residential buildings and city furniture, infrastructure for energy supply/water supply/electricity and heat supply and storage as well as special constructions like airports, ports or train stations.
What you‘ll get:
- A structured market segmentation
- A technology and value-chain mapping
- Application screenings, technology trees, fact sheets, comparative KPI matrices
- Expert workshops – providing participants with a practical foundation for business development, investment strategy, and innovation planning.
⏬ Download the Project Description
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
A modular platform for trucks, buses & off-highway vehicles
Can modular composite casings unlock cost and weight gains for low-volume commercial vehicles —and how?
Starting in Q3 of 2026
Duration: approx. 10 months
Plastic and composite battery casings have already demonstrated significant cost, weight and functional advantages in automotive applications. To leverage these benefits beyond passenger cars, modular and standardized enclosure concepts are needed that remain technically and economically viable even at low production volumes.
What you‘ll get:
The project evaluates whether a standardized, modular composite battery casing architecture can provide a technically and economically viable alternative to vehicle-specific designs. It quantifies the cost and weight benefits of bundling production volumes across models and manufacturers and defines scalable Heavy-Class and Compact-Class kit architectures for future commercial and off-highway applications.
WP 1: Requirements & commonality
WP 2: Kit definition & interfaces
WP 3: Reference concepts & CAE
WP 4: Manufacturing benchmark
WP 5: Regulatory compliance
WP 6: Business case & scaling
WP 7: Industrialization roadmap
⏬ Download the Project Description
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
From Today’s Production Vehicles to Tomorrow’s Thermal Runaway Solutions
Starting in Q3 of 2026
Duration: approx. 9 months
Obtain a comprehensive benchmark and deep insight into current and next-generation fire protection concepts for EV battery enclosures through independent benchmarking under realistic thermal runaway conditions.
What you‘ll get:
The project delivers a unique benchmark database of battery enclosure materials from production EVs and future R&D concepts, validated performance comparisons, cost-performance assessments, manufacturing feasibility evaluations and practical design guidelines to support future battery enclosure development.
WP 1: State-of-the-Art and Future Material Selection
WP 2: Definition of Test Profiles and Preparation
WP 3: Experimental Fire Protection Benchmarking
WP 4: Performance, Cost & Manufacturing Assessment
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
Current Joint Partner Projects
Open to Join
Experimental Testing & Benchmarking | Thermoset and Thermoplastic Materials, Direct Winding & Press-Fit Technology
Running Project – open to join
Duration: approx. 9 months
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.
- WP1: Definition od concepts to be made and tested
- WP2: Press-fit manufacturing and testing
- WP3: Direct winding manufacturing and testing
- WP4: Data analysis and final reporting
⏬ Download the Project Description
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
Benchmarking Systems for high-gradient heating and hot particle blasting for fire testing of housing and functional materials for EV battery casings
Running Project – open to join
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.
- WP1: Analysis of currently available test setups, providers and knowledge regarding testing of materials for structural and non-structural components of battery casings
- WP2: Implementation of relevant test setups of interest and benchmarking of test results.
- WP3: Development and implementation of improved systems for high-gradient heating and hot particle blasting
⏬ Download the Project Description
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
Trusted by Industry Leaders:
Benefits for Participants:
〉〉 Detailed, pre-competitive investigation of lightweight materials, systems or processes
〉〉 Combination of technical Knowhow and Market Intelligence
〉〉 Cost-effective budget based on joint cost sharing
〉〉 Contact to a broad network of industrial players
Recently Completed Joint Partner Projects
Development and benchmarking of design for-manufacturing-strategies to optimisematerial efficiency and cost
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.
- WP1: Screening of research landscape and market situation for thermoplastic pressure vessels for mobile and stationary applications (gas storage, transportation, utilization – vehicles, aerospace, industrial, energy).
- WP2: Development of alternative designs and manufacturing sequences for (sub) components/sections of thermoplastic type 4 and type 5 pressure vessels in a concurrent engineering approach. Technologies concerned e.g. winding, ATL, patching, fiber steering, braiding, forming, compression moulding, injection moulding, glueing, welding, tapes, LFT, sheets,…
- WP3: Cost- and performance benchmarking of the analysed strategies
⏬ Download the Project Description
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
A structured market and technology study mapping defence and space applications, materials, manufacturing routes, and functional benefits of plastics and polymer/non-polymer composites
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.
- Stage 1: Market segment overview and pilot analyzes, Workshop-based preevaluation and selection of applications with expected potential
- Stage 2: Systematic selection of attractive applications and components, detailed market and technology studies for selected applications and components
- Stage 3: Identification of highly attractive market opportunities, key players along the value chain
⏬ Download the Project Description
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
Insights into emerging battery storage technologies and their impact on design factors for battery casings
Do you know…
- … that the global battery market is set to grow by 34% annually until 2030? In the race for market share, new players are catching up.
- … that battery technologies, like solid-state not only have the potential of surpassing energy density compared to conventional LIBs, but also offer increased safety?
- … what are the material and design options for battery housings for cells with nonthermal propagation cell technologies?
What you‘ll get:
Expert assessment and evaluation of future battery technologies and their impact on requirements for material and design of battery casings.
- WP1: Screening of future battery technologies and trends with high market potential
- WP2: Impact analysis on future battery housing requirements, materials and design layouts
- WP3: Creation of design layouts and analysis of material variants.
- WP4: Business case scenarios for future design- and manufacturing concepts.
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 happens at a thermal runaway event for different battery cell chemistries? Will a flame result? What temperatures will occur?
- … how will the hot released gasses spread through the battery pack and put thermal and mechanical
- … how to predict whether a battery pack will safely survive a thermal runaway event according to regulations?
- … how effective different shielding materials avoid thermal propagation?
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.
- WP1: Analysis of state of the art and future battery cell types.
- WP2: Analysis of thermal runaway cell to cell propagation behaviour for different cell types
- WP3: Analysis of hot gas development and flow through the battery pack, pressure build-up and temperature loading on the battery casing structure.
- WP4: Example thermo-mechanical CAE analysis for different tray and lid layouts, using different 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
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?
- Providing improved efficiency, high power-to-weight ratio and compact design in combination with optimized performance is the key to powertrain evelopment. Composite-based rotor sleeves are particularly suitable for contributing to all of these development goals.
- Stabilizing the rotor at high rotational speeds in terms of strength and radial elongation with composite rotor sleeves enables tighter air gaps between rotor and stator and reduces eddy current losses compared to metal reinforcements.
- Some manufacturers of high-performance battery electric vehicles, drones and eVTOLs are already using composite rotor sleeves. The technology is now ready for spreading into mass applications, besides mobility also into industrial applications like power tools.
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.
- WP1: Screening of current and future applications, research landscape and market situation.
- WP2: Impact analysis on requirements, material, process and design layout.
- WP3: Business case scenarios for future design- and manufacturing concepts of selected highlight-applications.
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?
- Propellers and rotors are having their come-back for efficient flying and clean energy production with composite materials playing a key role.
- Electrical flying opens new sectors, demanding innovative propeller designs and composite mass production technologies to soar ahead with composites?
- More than 10% CAGR for general aviation generates new opportunities in propeller production.
- The demand for propellers only for commercial drones is estimated at up to 100 million parts per year.
- More than 9% CAGR for small wind turbines, rotors are essential not only for flying vehicles but also play a vital role in generating green energy
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.
- WP1: Screening of current market situation and evaluation of future potentials.
- WP2: Identification of latest materials, technologies, and manufacturing processes.
- WP3: Business case scenarios for future design- and manufacturing concepts of selected highlight-applications.
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:
- Provide market & industry insights
- Identification of hidden business potentials
- Share regulatory, standards & IP landscape info
- Present latest design, materials & manufacturing state of the art
- Create reference designs for evaluating KPIs
What you‘ll get:
- Discover trends in markets & technologies
- Understand value chain: materials, equipment, components, testing & development services
- Gain insights on design parameter impacts on KPIs using FEA analysis
- Evaluate reference designs to assess material, liner design, manufacturing methods, boss design & integration influence on vessel performance, cost & CO2 footprint
- Network with potential partners & customers at events
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:
- WP1: Screening of Market and Technology Developments
- WP2: Update on reference specification sheet
- WP3: Listing of concepts | Sketch design & dimensioning of multiple alternative concepts
- WP4: CAD visualization
WP5: Process Chain Definition & Business Case Analysis
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:
- WP1: Market and Technology Screening
- WP2: Inquiry of Standards & Requirements
- WP3: Definition of Specification Sheet for generic reference components
- WP4: Sketch design & Simple dimensioning of multiple concepts
- WP5: CAE optimizations and feasible design study
- WP6: Process Chain Definition & Business Case Analysis
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
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