• Additive manufacturing (3D printing)

    How the "EDAG Genesis" turned the automobile world upside down.

  • Standing the test of millions of years:

    EDAG's design (r)evolution

  • One recharge please!

    Why the smartphone is changing traffic conditions

  • Formula Student

    A case for EDAG

Innovative Pilot Projects

Ground-breaking innovation, technology and pilot projects

Our ground-breaking innovation, technology and pilot projects all document our commitment to the role we play as a proactive engineering partner. As ambassadors of our innovative power, they are indicative of our future potential, and stimulate dialogue.

We see ourselves as catalysts for innovation – for ourselves and our customers!

Our ability to define, specify and develop vehicle and system technologies is the basis of our technological leadership and the excellent reputation we enjoy on the market. 
The highly qualified, group-wide and interdisciplinary cooperation this calls for throughout the EDAG Group is an important driver for innovation and new technologies. In in-house projects such as the scalable electric platform LightCar technology carrier, our "EDAG Light Cocoon" concept car or the "Next Generation Spaceframe Concept 2.0", we repeatedly and visibly demonstrate our innovative strength. 

Our use cases

The following use cases are designed to demonstrate the future potential of these technologies while at the same time highlighting high engineering standards demanded and the opportunities for future vehicle development. We invite the parties concerned in the future value chain to join in the dialogue and get involved in further cooperation.

NextGenSpaceframe 2.0

Engineering process chain in aluminium using additive manufacturing and ultra-flexible profile bending for high-end lightweight design.

The technology of spaceframe 2.0, which was developed by EDAG with Constellium and Siemens Industry Software in cooperation with Laser Zentrum Nord, Concept Laser and BLM, demonstrates how it might be possible for a fully integrated engineering data process chain to be developed, both for additive manufacturing and for the development of load path-optimised extruded aluminium sections for vehicle bodies designed to meet load level requirements. The cooperation project was also joined by KW Automotive and 3M, to optimise the bonding technology. 


LightHinge+

Additively manufactured lightweight hood hinge with integrated pedestrian protection

The LightHinge+ hood hinge designed by EDAG in cooperation with voestalpine Additive Manufacturing (Düsseldorf) and Simufact Engineering (Hamburg) employs efficient software-aided engineering to make full use of the potential of additive manufacturing. It features the ultimate in weight reduction, the integration of a pedestrian protection function, warp tension and internal stress optimisation, toolless production for small series, and a low degree of finishing.


3M™ Glass Bubbles

A versatile lightweight filler

EDAG and 3M, the multi-technology company, present a new ingredient for an innovative recipe for lightweight design: depending on filling degree and formulation, they can bring about weight savings of up to 30 percent in the weight of plastic systems. At the IAA, EDAG and 3M presented a door trim featuring a new lightweight compound that highlights the fact that the innovative company's new filler makes plastic compounds lighter, while also ensuring compliance with vehicle manufacturers' and suppliers' technical requirements.

 


Lightweight Damping Material

Optimisation of acoustic load paths through material and engineering

With 3M's new damping technology "New.Lightweight Damping Material", EDAG and 3M joined forces at the IAA to present their cooperation in the field of acoustic engineering. 3M's new damping material was developed to reduce structure-borne noise in lightweight design applications for vehicles. Engineering specialists EDAG carried out a study to identify and evaluate interesting target applications aimed at weight reduction and goal-oriented function integration for the following fields of application: automobile, eMobility and commercial vehicles. To this end, EDAG developed a robot-assisted gripper concept which can be integrated in the vehicle assembly process.


ISB Elektro

Incremental swivel bending of scalable lightweight bearing structures

As part of the research project ISB Elektro (incremental swivel bending) funded by BMWi, EDAG and its partners the University of Siegen, ACS, Kirchhoff, Lewa and Kronenberg developed an innovative roll forming and bending technology for future vehicle concepts. The result is a cost-effective means of manufacturing for the flexible and variant-rich production of bearing structures. This opens up new and economical lightweight potential, for small and medium volumes in particular, for instance for eMobility or vehicle derivatives in the lightweight commercial vehicle sector. 

 


Service-oriented EE architecture

VISION 2025

In cooperation with automotive Ethernet specialists from TSN Systems, EDAG presents "Vision 2025", an initial draft of its automotive Ethernet networked zone architecture with weight savings of about 30 %. Not only does this service-oriented central computer-based method enable updates to be made, but new features can also be added without making changes to the hardware. Consisting of IP-free serial components, this reduces the development periods for ready-for-approval prototypes for startup companies.  

 


800V DC/DC Transformer

We look upon our innovative 800V DC/DC transformer, which was developed for motorsports, as a prime example of an E-Drive Solutions development.

Top efficiency and its extremely compact design are key characteristics of the transformer. Modern semi-conductor technology based on silicon carbide and gallium nitride permits high switching speeds and optimum loss reduction. An efficiency factor of up to 98% is achieved in this way. Systematic space optimisation and weight reduction provide particularly valuable support in the motorsports and automotive fields.


Media-free gripper

Flexible lightweight for manufacturing

With the in-house development of an additively manufactured "media free gripper", EDAG Production Solutions are looking firmly to the future. It was presented at the IAA 2017 to show how it will soon be possible to save both energy and space in the factory of the future. Gripper systems in production usually have pneumatic systems or electric motors for the grippers. These solutions come with a correspondingly high weight of their own and high mass inertia, and the robots that control these grippers must be dimensioned accordingly. With our "media free gripper", we have developed a passive gripper system, i.e. apart from the robot itself, it utilises no other power source. By dispensing with additional motors and sensors, weight savings of up to 75 percent are possible, compared to conventional systems. Further advantages are simple assembly and easy-to-change components following a crash. Standardised assemblies mean that warehousing space can be significantly minimised. Also, all parts required as spares or for modifications can simply be re-printed using the additive manufacturing method.

 


Scrum

Agile project management

SCRUM is an agile process in which the team gets together at short intervals (generally every day), to discuss how work is progressing and exchange ideas. Input from the community is also examined and evaluated several times a day. We can take note of the new demands and ideas from our team or also the community at short intervals, and summarise, prioritise and incorporate them in small work packages known as sprints. Particularly in the concept phase of a radically new vehicle and mobility concept like #collectivio, which more than anything else depends on the input of future users, SCRUM is the perfect means of demonstrating how the engineering process can be improved in the future. 

 


Trive.park

Stress-free booking, parking and paying via app

This new form of smart parking is being tested in selected car parks, as part of an initial field trial that started at the beginning of 2018. Following Munich and Fürth, four additional car parks run by the car park provider "ParkOne" in Berlin are now being included in the field trial. The product trive.park demonstrates that the increasing digitalisation of the automotive industry is creating new business segments with enormous potential.


Sustainability

Economical lightweight door for commercial vehicles

It might sound simple at the outset, but this is nevertheless a far-reaching change: the weight of a door for long-distance trucks designed to meet future legal requirements has been reduced by 20% - at no extra cost. The door gives the driver a maximum viewing angle, and has been optimised to provide pedestrian protection. "WiLeitNu" is a project sponsored by the Federal Ministry for Economic Affairs and Energy, on which EDAG worked in close cooperation with partners Fischer Hydroforming and Muhr Metalltechnik. A virtual model was presented for the first time at the IAA 2018, and the real prototype will follow in 2020.


Future mobility

BatteRANGE, a modular, scalable chassis concept  

For years, EDAG has been pursuing the vision of the commercial vehicle chassis 2.0. Taking into account the requirements of alternative drive trains, an innovative concept has been created: BatteRANGE offers full variability and scalability, and features a modular chassis architecture, which makes it possible to configure the appropriate chassis for every application from the diesel engine to the fuel cell. For the wheel formulas 4x2 and 6x2, it enables different drive trains to be fitted to everything from the semi-trailer truck to the motor coach, according to their specific requirements. To make this possible, the truck chassis is divided into three. The front section is made up of large cast parts which create the space necessary for the integration of an independent wheel suspension. The scalable centre section of the chassis accommodates the energy storage system and drive components. In the rear section, the axle combinations required are conventionally connected. 


Digitalisation

VR training tool for car body painters

Visitors to the IAA Commercial Vehicles show were able to test a new VR training tool for car body painters at the EDAG stand: state-of-the-art technology transports car body painters to a virtual paint shop where, holding a real - though empty - paint gun, they can practice their painting technique under realistic conditions – wherever they are, and without wasting resources. An integrated feedback system supplies notes on paint thickness, spray angle and speed.