International Transport Manufacturer November 2025
The transport industry stands on the threshold of its most transformative decade yet. Automation and electrification are no longer emerging trends; they are defining the direction of mobility across every mode of transport. From autonomous trucks and smart logistics to electric buses, ships, and aircraft (page 6), technology is reshaping how we move people and goods with unprecedented precision and efficiency.
What’s most exciting is how convergence is driving innovation. Advances in battery technologies (page 8), more sustainable materials (pages 13, 14 and 16), and zero-emission concepts (page 20) are not developing in isolation - they’re reinforcing one another, creating smarter, cleaner, and more adaptive transport ecosystems. Manufacturers and suppliers are now racing to integrate these technologies into scalable, sustainable solutions while balancing performance, safety, and cost.
However, the shift is not purely technical. Electrification and automation (page 26) demand new skills, fresh collaboration models, and a rethinking of traditional supply chains (page 32). As software becomes as critical as hardware, the industry must embrace continuous learning and cross-sector partnerships to stay ahead (page 40).
This issue highlights how leading innovators are turning these challenges into opportunities - proving that the future of transport will be shaped not only by technology itself, but by how intelligently and collaboratively we apply it. These themes will be reflected at the upcoming industry events previewed on page 43.
Hayley Everett Editor
AVIATION AUTOMATION
How new metrology technologies are redefining the way aerospace manufacturers build, inspect and modernise their operations
ELECTRIC EVOLUTION
The global race to reinvent EV powertrain technologies
16 FREE FROM ‘FOREVER CHEMICALS’
A recent report from IDTechEx offers a path to PFAS-free lithium-ion batteries
E-MOBILITY
18 GRANTING CHANGE
Delving into new data on the early impacts of the UK government’s new Electric Car Grant
20 ZERO-EMISSION TECHNOLOGY
How lead-free aluminium alloys can drive compliance and
SUSTAINABILITY ON SHOW
Advancing sustainable composites with a new show car collaboration
Rugged data infrastructure for the zero-emission vehicle supply chain
Leading the charge in hybridelectric aircraft
A newly-launched cloud platform is accelerating vehicle battery cell selection by up to six months
Compact, flexible and sustainable testing for the next generation of
New air springs boost safety and durability for commercial fleets
New funding is helping to advance the development of self-driving trains
Adopting digital quality management practices across transport manufacturing
Multi-talented sensor for commercial vehicle testing under tough conditions
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Jerry Ramsdale
EDITOR
Hayley Everett heverett@setform.com
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Unveiling a new range of compact automotive surgeprotection Zener diodes for nextgeneration vehicle electronics
Wevo has launched a highperformance 2K silicone adhesive for thermal management in EV batteries and power electronics
Rounding up the latest training and upskilling initiatives from across the transport sector
ADVANCING INTEGRATED VEHICLE TECHNOLOGIES
What to expect at the 17th Annual Automotive Chassis Systems Europe 2025
DRIVING THE FUTURE OF THE AUTOMOTIVE AFTERMARKET
Dubai Automechanika takes place 9-11 December
INNOVATION, INTEGRATION AND GLOBAL COLLABORATION
Automechanika Shanghai returns in November
Setform’s international magazine for transport is published quarterly and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Process, Design, Energy, Oil and Gas, Mining and Power.
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AVIATION AUTOMATION
Lydia Arundel explores how new metrology and digitalisation technologies are stepping up to redefine the way aerospace manufacturers build, inspect, and modernise their operations
The aerospace industry is entering a new period of high-volume production, with Airbus planning to increase its A320 output from around 45-50 per month to 75 by 2026, and OEMs and suppliers around the world working to meet the demand. But with longstanding facilities, skills shortages, and rising pressure to decrease costs, the challenge is not just about modernising how aircraft are made but also about increasing output.
Hexagon has created a portfolio of technologies to digitise production environments and automate quality assurance, including laser trackers and inspection cells, digital twins, and next-generation coordinate measuring machines (CMMs). These innovations provide a means to transform the way aerospace manufacturers can manage space, precision, and throughput.
AUTOMATING INSPECTION WITH ATS800
The Leica Absolute Tracker ATS800 is a portable laser tracker that can cut inspection times from hours to minutes and accurately measure from 40 metres away, without any scaffolding or targets. The ATS800 also makes the overnight “third shift” a reality on the factory floor.
By integrating reflector tracking with real-time feedback, highprecision tasks are simplified, including fuselage assembly and composite layups. At the same time, its FeatureDetect function can automatically recognise features from CAD files or panoramic camera feeds without the requirement for any manual programming.
The ATS800 is automation-ready and is able to be mounted on robot
The service can provide results four times faster than traditional mapping and can decrease travel and on-site meetings by up to 70%
arms, gantries, or AMRs for lightsout inspections, fitting seamlessly into existing metrology software ecosystems, such as PC-DMIS and SpatialAnalyser. Having already been deployed in Hexagon’s automated PRESTO Quality Stations, the ATS800 has proven its ability to cope with large and complex structures with minimal repositioning, even on reflective surfaces.
DIGITAL TWINS FOR LEGACY FACILITIES
Inspection technology is taking on quality and throughput; facility modernisation is another vital part of the puzzle towards transforming aerospace production. Many aerospace plants have managed to evolve over decades, despite having to use layouts and data that no longer reflect operational reality. Hexagons Digital Factory-as-a-Service is able to address this by providing fast, millimetreaccurate 3D scans of production sites, transforming them into immersive, interactive digital replicas.
By using these digital twins, manufacturers can plan new production cells, test automation scenarios, and optimise space utilisation before any physical changes are made. The service can provide results four times faster than traditional mapping and can decrease travel and on-site meetings by up to 70%. It is also fully scalable across single or multiple sites, supporting traceability and digital twin strategies as aerospace companies scale up their production.
Nicolas Lachaud-Bandres, vice president of Industry Solutions at Hexagon, says, “With many factories adapted repeatedly over the decades, reliable layout data is often lacking. Digital Factory as-a-Service provides the clarity and control needed to modernise efficiently and ramp up without costly surprises.”
The PRESTO M with Hyperscan
MAESTRO: NEXTGENERATION CMM
Maestro is a fully re-engineered coordinate measuring machine designed to meet modern manufacturing demands. Its digital architecture, which features advanced sensors, a single-cable system and new firmware, can provide sub-micron precision with speed, while also simplifying programming for experts and new operators through an intuitive interface and SaaS metrology apps.
Designed for IIoT integration via Hexagon’s Nexus platform, Maestro connects quality data across design and production teams, enabling datadriven decision-making. Its modular design ensures manufacturers can scale and upgrade as production evolves, making it a future-proof investment for high-precision aerospace applications.
Jörg Deller, general manager Stationary Metrology Devices, Hexagon’s Manufacturing Intelligence division, says, “By rethinking our hardware and software from the ground up, rather than iterating on existing systems, we’ve had the freedom to create a high-accuracy inspection solution that is so intuitive that anyone from experts to new hires are significantly more productive. Meeting the needs of industry headon, Maestro’s digital backbone also makes it straightforward to integrate into modern connected factories, so stakeholders can improve quality quickly and definitively.”
PRESTO EL: SCALING UP INSPECTION CAPACITY
For the larger aerospace components, the Presto XL from Hexagon is the largest addition to its automated inspection cell range and has been designed for global deployment in just 16 weeks. The system can accelerate inspections by 50% and reduce hidden manufacturing costs.
Presto XL combines mobile trackers and scanners with Hexagon’s blueline laser scanning and absolute positioning technology to enable quick inspection of large fuselage panels, doors, and wing ribs, even under challenging lighting conditions. It can be reprogrammed in hours by a single metrologist, without robot expertise, offering the flexibility aerospace OEMs require to keep up with rising output.
The ATS800 inspecting an aircraft fuselage
A UNIFIED VISION FOR AEROSPACE MODERNISATION
As a whole, the ATS800, Digital Factory-as-a-service, Maestro and Presto XL represent a coherent strategy to digitise and automate aerospace manufacturing. By combining real-time inspection, spatial intelligence, and next-generation metrology, Hexagon can provide manufacturers with the necessary tools to increase production without compromising precision.
As the aerospace sector prepares for its most significant production rampup in decades, technologies like these may prove essential in bridging the gap between legacy infrastructure and the smart factories of the future.
The MAESTRO re-engineered coordinate measuring machine
ELECTRIC EVOLUTION
The global race to reinvent electric vehicle powertrain technologies
The automotive industry is entering a defining phase of transformation. Electrification is no longer limited to batterypowered drivetrains but is increasingly encompassing an expanding ecosystem of hybrid systems, hydrogen fuel cells, advanced semiconductors, modular software platforms, and new manufacturing concepts. Across every major region, OEMs and suppliers are investing heavily in next-generation powertrain systems that promise greater efficiency, sustainability, and scalability.
From BMW’s multi-energy vehicle strategy and Nissan’s hybrid
engine breakthroughs, to Infineon’s semiconductor advancements, Volkswagen and XPENG’s E/E architecture collaboration, and Ford’s new EV platform, the trajectory is clear: innovation in EV powertrains now extends beyond propulsion to include energy management, digitalisation, and intelligent software integration.
A TECH-OPEN STRATEGY
The BMW Group has taken a unique approach to electrification with its announcement of the new BMW X5, which will be available with five different drivetrain technologies:
battery-electric, plug-in hybrid, petrol, diesel, and hydrogen fuel cell. This marks the industry’s first production vehicle designed to accommodate such a wide range of powertrains on a single platform.
BMW’s strategy reflects what it calls a technology-open approach, recognising that diverse regional markets and customer needs will require different solutions for decarbonisation. “By launching the new BMW X5 with a choice of five drive system variants, we are once again demonstrating our leading position as a technology pioneer,” says Joachim Post, BMW board member for development.
By launching the new BMW X5 with a choice of five drive system variants, we are once again demonstrating our leading position as a technology pioneer
Testing the BMW iX5 Hydrogen
At the core of BMW’s hydrogen program is the iX5 Hydrogen, developed in partnership with Toyota Motor Corporation. Its third-generation fuel cell system is more compact, efficient, and powerful, achieving higher output while reducing energy consumption. Hydrogen storage and balance-of-plant components are integrated in BMW’s Munich and Landshut facilities, demonstrating the company’s extremely deep manufacturing flexibility.
Beyond the vehicle itself, BMW is addressing the infrastructure challenge through the HyMoS (Hydrogen Mobility at Scale) initiative. In collaboration with industry partners, HyMoS aims to establish hydrogen ecosystems and refuelling stations in metropolitan areas, pooling demand from commercial fleets and passenger vehicles to enhance the economic viability of hydrogen mobility. The first pilot is already underway in Germany and France, paving the way for broader deployment in Europe.
COLD-SPRAY TECH
In Japan, Nissan has achieved a world first by applying cold spray technology to the valve seats of its new 1.5-litre turbocharged generator engine, developed exclusively for the thirdgeneration e-POWER hybrid powertrain. The innovation enables superior combustion efficiency and reduced component mass, while enhancing heat dissipation and durability.
Cold spray is an additive manufacturing process that deposits
metallic powders at supersonic velocity without melting the substrate. This eliminates traditional pressfitted valve seats, allowing engineers to optimise intake port geometry for improved airflow and “tumble” motion – a critical factor in achieving the engine’s 42% thermal efficiency under Nissan’s STARC 2 concept.
The new ZR15DDTe engine serves as a power generator within Nissan’s e-POWER system, which drives the wheels exclusively through an electric motor. The engine’s only role is to produce electricity, providing the seamless feel of an EV without requiring external charging. The powertrain integrates a compact 5-in-
1 modular electric unit, combining the inverter, reducer, motor, generator, and increaser into a lighter and more efficient package.
This approach represents an innovative middle ground between full electrification and conventional hybrid systems, combining electric drive with optimised combustion for extended range and reduced emissions. The technology will debut in the Qashqai and expand to models such as the Rogue and Elgrand from 2026.
FRESH PLATFORM THINKING
In the US, Ford Motor Company is executing a $5 billion investment plan to develop a Universal EV Platform and Universal EV Production System, introducing a scalable foundation for its next generation of affordable electric vehicles.
The first model, a mid-size electric pickup truck, will launch in 2027 from the Louisville Assembly Plant. Designed to be “as fast as a Mustang EcoBoost” and priced around $30,000, the truck aims to democratise electric mobility in the highly competitive midsize segment. The Universal EV Platform allows Ford to produce a family of vehicles that share structural components, power electronics, and battery systems –supporting rapid development cycles and OTA (over-the-air) software
Doug Field, the chief EV, digital and design officer at Ford Motor Company, speaks at Louisville Assembly Plant as Ford shares its plans to design and assemble breakthrough electric vehicles in America
EV.OS is a flexible and AI-centric software platform
updates. The Universal EV Production System, meanwhile, reimagines assembly line operations with modular subassemblies, digital twins, and automated quality assurance for speed and safety.
This integrated ecosystem positions Ford to compete directly with lowercost EV entrants while maintaining domestic manufacturing leadership. The company is also investing heavily in BlueOval Battery Park Michigan, where it will produce advanced prismatic LFP (lithium iron phosphate) batteries at scale, reducing dependence on imported materials.
SEMICONDUCTORS DRIVE EFFICIENCY
No electric powertrain can achieve high efficiency without advanced semiconductor components. Recognising this, Infineon Technologies AG has expanded its OptiMOS 6 portfolio with a new family of automotive-grade 150 V MOSFETs, addressing the growing demand for high-performance power conversion in EV and hybrid systems. These components are optimised for HV/LV DC/DC converters, traction inverters for electric two-wheelers, and auxiliary power systems in passenger EVs. With RDS(on) values as low as 2.5mΩ and thermal resistance down to 0.4kW, the new MOSFETs deliver exceptional conduction efficiency and heat dissipation, enabling designers to reduce cooling requirements and system cost.
Available in TOLL, TOLG, and TOLT packages, the devices offer design flexibility across compact and thermally constrained environments. The TOLT variant, featuring top-side cooling, is especially suited to highfrequency switching applications such as compact traction inverters. All devices meet AEC-Q101 and PPAP
standards, ensuring qualification for high-volume automotive use. Infineon’s expansion underscores how power electronics are becoming a critical lever in improving energy conversion and extending driving range in nextgeneration EVs.
UNIFYING E/E ARCHITECTURES
In China, XPENG and the Volkswagen Group have advanced their strategic partnership by entering an expanded agreement to co-develop an Electrical/ Electronic (E/E) Architecture for cross-platform applications. Initially created for EVs, the system will now be extended to Volkswagen’s internal combustion and plug-in hybrid platforms in China.
The collaboration accelerates the Group’s software-defined vehicle (SDV) roadmap, enabling unified data, faster software iteration, and OTA update capabilities across vehicle types. The crosspowertrain ‘platformisation’ of the E/E Architecture not only reduces development time but also improves cost efficiency through shared hardware modules and standardised communication protocols.
Volkswagen executives describe this as a major step toward integrating combustion and EV architectures under one digital backbone. Ralf Brandstätter, CEO of Volkswagen Group China, explains: “By extending the China Electronic Architecture to our combustion engine fleet, we’re strengthening our technological leadership and reducing our cost base – ensuring competitiveness in China’s intensely dynamic market.”
For XPENG, the partnership deepens its role as a software and systems innovator, reinforcing its position as a strategic technology supplier for global OEMs.
SOFTWARE-DEFINED POWERTRAINS
As vehicles become more like rolling
Each of the three package types offers specific advantages: the TOLL package enables a compact design, the TOLG allows for high robustness against thermal-mechanical stress, the TOLT features a top-side cooling concept
computers, the software layer of the powertrain is emerging as a primary differentiator. To that end, Elektrobit and Foxconn have entered a joint development agreement to create EV.OS, a modular, AI-centric operating system designed to power the next generation of softwaredefined electric vehicles.
The platform combines Elektrobit’s embedded software expertise with Foxconn’s hardware integration capabilities to create an end-to-end EV ecosystem, including a reference E/E architecture (EV.EEA), a standardised vehicle operating system, and an application layer for third-party developers. EV.OS supports real-time ECU management, service-oriented architectures, and a semantic vehicle API that enables flexible software updates across functional domains from energy management and charging to autonomous functions. The project is supported by a CI/CT/ CD toolchain (continuous integration, testing, and deployment) and a Level 3 virtualised development environment to accelerate validation and rollout.
“By combining Elektrobit’s software expertise with Foxconn’s manufacturing innovation, we’re creating a scalable platform that reduces complexity and shortens development cycles,” says Maria Anhalt, CEO of Elektrobit.
ELECTRIFICATION: A NEW DEFINITION?
Across these initiatives, a common theme emerges: electrification is diversifying. The new powertrain landscape encompasses hydrogen fuel cells, hybrid electric generators, advanced semiconductor power electronics, and software-defined architectures, each serving a distinct role. What unites them is a shift from siloed vehicle design to system-level thinking where propulsion, software, and manufacturing are engineered as interconnected elements of one digital ecosystem.
Nissan’s new ZR15DDTe engine cylinder head
As the automotive sector accelerates toward a lighter, cleaner, and more circular future, material innovation has become a defining competitive advantage. Aluminium — already central to vehicle weight reduction and efficiency — is taking on an even more strategic role as new European regulations redefine environmental performance standards. At the forefront of this transition is Eural Gnutti, a leading manufacturer of drawn aluminium bars for mechanical processing and a major European producer of extruded bars and profiles. Founded in 1968 in Rovato, Italy, Eural Gnutti operates production sites in Rovato and Pontevico, with 416 employees and 2023 revenues of €310 million. Backed by a growing international presence in the US and Germany, the company continues to lead the evolution of lead-free, highperformance aluminium alloys that align with both engineering excellence and environmental responsibility.
ANTICIPATING THE NEW ELV REGULATION
The forthcoming End-of-Life Vehicles (ELV) Regulation, expected to enter into force in late 2027, represents a major evolution in how vehicles are designed, built, and recycled. The updated framework reduces the allowable lead content in automotive materials from 0.4% to 0.1%, tightening
The company produces lead-free, high-performance aluminium alloys Replacing
LEAD-FREE LIGHTWEIGHTING
How lead-free aluminium alloys can drive compliance and sustainability in nextgeneration vehicles
compliance thresholds and requiring full lifecycle accountability from manufacturers.
Beyond emissions and recyclability, the new regulation links vehicle production directly to the circular economy, mandating design strategies that prioritise reuse, recovery, and traceability of raw materials, including aluminium. Automotive manufacturers must therefore depend on suppliers capable of delivering both technical performance and regulatory assurance across the value chain.
ALUMINIUM FOR LIGHTWEIGHTING AND CIRCULARITY
Aluminium’s combination of lightness, strength, and recyclability makes it indispensable for sustainable vehicle design. Replacing steel with aluminium can cut component weight by around a third. For every 100 kilograms removed, manufacturers can save roughly 3.5 litres of fuel per 1,000 kilometres, equating to a reduction of two tonnes of CO2 over a vehicle’s lifetime.
Eural’s expertise in advanced alloys directly supports this shift. Its products are already integral to critical safety and performance systems — from transmission components and clutch actuators to braking, steering, and airbag mechanisms. The company’s extruded profiles are also widely used in heat exchangers, pump bodies, bushings, and anti-vibration systems.
6026LF: THE LEAD-FREE ALTERNATIVE
Eural’s flagship innovation, the 6026LF (Lead-Free) alloy, sets a new benchmark for machinable, sustainable aluminium. Developed as a direct substitute for the conventional 6026 and 6064A alloys, 6026LF delivers comparable mechanical strength, excellent chip formation, and high surface finish quality, even after hard anodising.
Already validated by automotive OEMs, the alloy combines precision machinability with full compliance to the revised ELV requirements — offering manufacturers a future-proof solution for applications such as braking systems, safety assemblies, and high-pressure components. “Its mechanical properties, combined with the absence of lead and full compliance with new regulatory requirements, make it a reliable and sustainable alternative,” explains Paolo Pilato, sales manager at Eural.
TRACEABILITY AND RESPONSIBLE SOURCING
Eural Gnutti ensures complete traceability through the International Material Data System (IMDS), now mandatory across the automotive supply chain. In parallel, the Supplier Assurance portal monitors ethical and environmental performance, supporting due-diligence obligations under EU law. Reflecting its progress in sustainability governance, Eural’s ASI certification rating improved from D54 in 2023 to B80 in 2025.
SUSTAINABILITY ON SHOW
The future of automotive materials is increasingly defined by sustainability and innovation – and a new collaboration between Bcomp and Cupra demonstrates that high performance and environmental responsibility can go hand in hand. The recently unveiled Cupra Tindaya Showcar, showcased at IAA Mobility 2025 in Munich, integrates ampliTex flax-fibre composites developed by Swiss cleantech pioneer Bcomp, highlighting how bio-based materials can deliver both technical excellence and design sophistication in nextgeneration vehicles.
FLAX FIBRE COMPOSITES
Bcomp’s ampliTex technology replaces traditional synthetic reinforcements, such as carbon fibre, with a renewable, plant-based alternative derived from European flax. Engineered in a twill 2/2 weave, ampliTex achieves up to 85% CO2 reduction compared to conventional carbon-fibre composites across its life cycle. The material’s natural fibre architecture provides a high strength-to-weight ratio, inherent vibration damping, and superior impact resistance – properties critical for both interior and exterior automotive components.
In the Tindaya, ampliTex is featured in Cupra’s signature bucket seats and front bumper, marking one of the first concept vehicles to showcase natural-fibre composites in both visible interior and semi-structural exterior applications. Working alongside Cupra’s Colour, Materials and Finish (CMF) team, Bcomp engineers co-developed a custom copper-toned finish, merging advanced materials with the brand’s warm, metallic aesthetic inspired by volcanic earth tones.
ENGINEERING A NEW MATERIAL IDENTITY
The Tindaya’s name – drawn from a volcanic mountain in Fuerteventura –underscores Cupra’s connection to raw
Advancing sustainable composites with a new show car collaboration
For engineers, the integration of ampliTex into exterior panels and seating structures represents a significant step forward
Bcomp’s ampliTex technology replaces traditional synthetic reinforcements
natural elements. This theme extends to material selection and finish, where the use of ampliTex aligns with the brand’s push to integrate sustainability throughout the vehicle lifecycle. By replacing synthetic fibres with flaxbased composites, Cupra reduces dependency on petroleum-derived materials while cutting embodied carbon without sacrificing performance or design freedom.
For engineers, the integration of ampliTex into exterior panels and seating structures represents a significant step forward. Natural-fibre composites are not only lighter but also offer improved crash energy absorption and reduced acoustic transmission, enhancing both efficiency and comfort. Their compatibility with standard resin systems and moulding processes also supports scalability for future production vehicles.
FROM CONCEPT TO PRODUCTION
The collaboration between Bcomp and Cupra extends beyond concept innovation. The two companies first worked together on the Cupra Born VZ, the brand’s electric performance model now in series production, where ampliTex was used for interior
trim elements. The success of that partnership has laid the groundwork for expanding the use of bio-based composites from design prototypes to mass-market applications.
A NEW BENCHMARK FOR SUSTAINABLE MOBILITY
“For CUPRA, sustainability goes beyond simply swapping internal combustion engines for electric powertrains,” says Nicolas Samson, sales manager at Bcomp. “By replacing conventional synthetic materials, they are leading the way for the future of mobility.”
Francesca Sangalli, head of colour & trim concept & strategy at Cupra, adds: “Bcomp’s material expertise has enabled us to blend technology and sustainability. We’ve proven that natural fibre composites can deliver the same exceptional aesthetics and performance as synthetic alternatives.”
According to the partners, Tindaya Showcar is not only a design exercise but also a technical statement. By merging bio-based materials science with automotive engineering, Bcomp and Cupra are demonstrating how responsible innovation can shape a new era of lightweight, circular, and aesthetic mobility.
FREE FROM ‘FOREVER CHEMICALS’
A recent report from IDTechEx offers a path to PFAS-free lithium-ion batteries
As global regulators tighten restrictions on per- and polyfluoroalkyl substances (PFAS) — the so-called “forever chemicals” — the battery industry faces growing pressure to eliminate these persistent compounds from lithium-ion cell manufacturing. A new report from IDTechEx, ‘Additives for Li-ion Batteries and PFAS-Free Batteries 2026–2036: Technologies, Players, Forecasts’, outlines how novel polymer systems and electrolyte additives are emerging as viable replacements for PFAS, signalling the beginning of a new era in sustainable battery chemistry.
PERFORMANCE AT AN ENVIRONMENTAL COST
PFAS encompass a vast family of over 5,000 fluorinated compounds known for their chemical stability, thermal resistance, and non-stick properties. These same characteristics have made them invaluable to modern energy storage systems, where stability and adhesion are critical for cell longevity and safety.
In lithium-ion batteries, PFAS materials serve multiple roles. The most widespread use is as binders in electrode formulations. Polyvinylidene fluoride (PVDF), a PFAS-based polymer, dominates
cathode binder systems due to its strong adhesion to active materials and conductive additives, as well as its electrochemical inertness. On the anode side, however, many manufacturers have already shifted toward water-based, non-fluorinated binders such as carboxymethyl cellulose (CMC) and styrenebutadiene rubber (SBR).
As manufacturing transitions toward dry electrode processing, where solvent-free coating methods reduce energy consumption and waste, PVDF is increasingly being replaced with polytetrafluoroethylene (PTFE) – another fluoropolymer in the PFAS
WHAT GOES INTO A PFAS-FREE BATTERY?
PFAS-free cells will require changes to the materials used as binders and electrolyte additives
Emerging battery trends are altering what additives are used in Li-ion cells
family. In electrolytes, PFAS-based compounds also appear as functional additives, including fluorinated lithium salts, flame retardants, and co-solvents such as hydrofluoroethers, all designed to enhance conductivity, interfacial stability, and safety.
Despite these benefits, PFAS materials are now facing unprecedented scrutiny due to their persistence in the environment, bioaccumulative properties, and links to health concerns such as cancer and developmental effects. With the European Union, the US Environmental Protection Agency, and other bodies proposing strict limitations or outright bans on PFAS use, the battery sector is rapidly exploring ways to replace these materials without compromising cell performance.
THE SEARCH FOR VIABLE ALTERNATIVES
According to IDTechEx, the path toward PFAS-free batteries requires coordinated innovation across both binder and electrolyte additive domains.
Replacing PFAS-based binders like PVDF and PTFE demands materials that maintain strong particle adhesion, chemical resistance, and mechanical flexibility under highvoltage conditions. Several promising candidates have emerged. Polyacrylic acid (PAA) and polyethylene oxide (PEO) are among the most advanced non-fluorinated binders currently being evaluated. PAA, a water-soluble polymer, offers strong adhesion and good compatibility with aqueous
electrode processing, reducing the need for toxic solvents such as NMP (N-methyl-2-pyrrolidone). PEO, meanwhile, provides ionic conductivity and flexibility, attributes valuable for both electrodes and solid-state electrolyte interfaces.
Some manufacturers are already implementing PFAS-free solutions. Leclanché, for instance, has publicly announced the removal of PFAS from its binder systems. Meanwhile, innovators such as Nanoramic Laboratories and 24M Technologies are developing binder-free electrode architectures that eliminate polymeric binders altogether, simplifying the electrode structure while improving recyclability and throughput.
Electrolyte additives represent another significant PFAS use case. Traditionally, fluorinated compounds have been used to stabilie the solidelectrolyte interphase (SEI) and suppress gas generation under high voltage or temperature stress. Moving away from these requires careful reformulation to preserve safety and stability.
IDTechEx identifies several commercially viable non-fluorinated additives already in use. Lithium bis(oxalato)borate (LiBOB) is gaining traction as an SEI-forming additive that improves cycle life and hightemperature performance without relying on PFAS. Vinylene carbonate (VC) is another well-established additive, enhancing SEI stability and protecting the anode surface in conventional and high-energy chemistries alike.
More recently, electrolyte specialists such as E-Lyte Innovations have announced PFAS-free electrolyte formulations, demonstrating that functional replacements can meet stringent performance criteria. However, as IDTechEx notes, PFAS remediation is not simply a matter of one-to-one substitution. Electrolyte formulations are complex, and replacing a single additive can alter multiple interdependent parameters, including ionic conductivity, viscosity, and SEI composition. This makes collaborative R&D between material suppliers, cell manufacturers, and OEMs essential.
REGULATORY DRIVERS
The transition toward PFASfree batteries comes at a pivotal time for the transport and energy storage industries. With lithiumion technologies underpinning the global shift to electric mobility and renewable energy integration, regulatory compliance is becoming a key differentiator for suppliers.
IDTechEx forecasts that the market for non-PFAS battery additives will surpass $2 billion by 2036, as both environmental policy and supply chain sustainability drive demand for safer, more circular chemistries. Europe is expected to lead adoption due to proactive regulation and strong public concern, followed by North America and East Asia as local laws and OEM sustainability mandates align.
Material qualification timelines and manufacturing validation remain major challenges. Developing new binders or additives is not only a matter of chemistry – it requires comprehensive testing across the entire battery lifecycle, from slurry mixing to recycling. Compatibility with established electrode fabrication processes and the cost of retooling are key barriers to rapid implementation. Despite these hurdles, momentum toward PFAS elimination is clearly accelerating. “Forever chemicals” are becoming increasingly untenable in an industry built on the promise of clean technology. Through a combination of polymer innovation, additive reformulation, and nextgeneration electrode design, the sector is making measurable progress toward sustainable, PFAS-free batteries.
GRANTING CHANGE
We delve into new data on the early impacts of the UK government’s new Electric Car Grant
Early data suggests the UK’s new Electric Car Grant is sending a strong market signal, but may be rewarding existing EV buyers rather than driving new ones. The UK Government’s Electric Car Grant (ECG) - a £650 million scheme launched in July 2025 to make battery electric vehicles (BEVs) more affordable - has shown a mixed impact in its first full month of operation.
According to New AutoMotive’s new analysis, “That Fuzzy Feeling: A First Analysis of the Impact of the Electric Car Grant,” BEV models eligible for the scheme accounted for 23.8% of new registrations in September 2025, identical to their share before the grant was announced. The finding suggests that the ECG has yet to expand the total market for electric cars, instead largely subsidising vehicles that consumers were already planning to buy.
LIMITED CHANGE IN CONSUMER BEHAVIOUR
The report, based on registration data from the DVLA and DVSA, shows modest evidence of “within-brand switching” - buyers opting for an ECGeligible model from a manufacturer instead of a non-eligible version.
However, there is little indication that the grant has attracted entirely new EV buyers or significantly reshaped the overall market balance.
“The Electric Car Grant has sent a strong signal of government commitment to EVs, supporting consumer confidence, the expanding used market and green jobs in markets closer to home,” says David Farrar, policy manager at New AutoMotive. “But it isn’t yet clear that it’s prompting consumers to consider buying cars that they wouldn’t have gone ahead and bought anyway.”
Farrar added that the fund - intended to last until 2028/29 - could be depleted two years early at its current rate of spending. “Policies at no taxpayer cost at all could support 10 million in making the switch by lowering the cost of public charging and making it easier to charge at home,” he adds.
WINNERS AND LOSERS
Although the ECG has not yet moved the overall market share needle, its impact varies widely between models. The Ford Puma and Nissan Ariya - both eligible for the higher “Band 2” grant - saw notable gains in registrations. By contrast, several high-volume models from VW Group (including Skoda, Volkswagen and
Cupra) and Renault lost ground, despite also being covered by the grant. Meanwhile, manufacturer-funded “ECG-style” discounts from brands such as MG and Volvo proved effective, boosting market share without direct public subsidy. New AutoMotive notes that these company-backed schemes may have delivered stronger shortterm results than the governmentfunded ECG itself.
HIGH COST, LIMITED REACH
The fiscal implications of the scheme are substantial. New AutoMotive estimates that the first month alone may have cost up to £31 million, with Ford and VW Group and their customers capturing nearly two-thirds of the benefit.
If monthly spending continues at this pace, the entire £650 million budget could be exhausted by 2026/27, one to two years earlier than planned. The grant can support at most 400,000 car buyers, a fraction of the 10 million motorists who face structural barriers to affordable EV ownership.
Despite the high cost, the ECG’s direct market impact therefore appears modest. The data implies that many buyers of eligible models would have proceeded with their purchases
regardless of the subsidy, raising questions about the scheme’s cost-effectiveness.
A STRONG POLICY SIGNAL
Where the ECG appears most effective is in market signalling, however. The grant has reassured both consumers and industry that government remains committed to the EV transition after several years of shifting policy. Its introduction also triggered a competitive response from non-eligible brands, which have introduced price cuts or new finance incentives to remain attractive, further increasing consumer savings. In that sense, the ECG may have amplified its indirect impact through market competition rather than direct sales. Moreover, the visibility of the scheme has driven marketing momentum across the sector. Automakers offering both government-supported and self-funded discounts have invested in advertising to highlight their affordability. Even firms without any grants have stepped up campaigns to emphasise the value of their existing EV offers. This “free money effect,” as New AutoMotive describes it, has generated substantial publicity for electric cars overall.
THE CHARGING CHALLENGE
The analysis also highlights a persistent inequality at the heart of the UK’s EV market: charging access. Around 10 million drivers - renters, leaseholders and those without offstreet parking - face running costs up to seven times higher than those who can charge at home.
ZapMap data show that slow public charging averages 51p/kWh, compared with around 7p/kWh for off-peak home charging. As long as this gap persists, lower-income and urban households will remain excluded from the full economic benefits of going electric.
New AutoMotive argues that addressing these disparities through planning and infrastructure reforms would deliver greater long-term impact at minimal taxpayer cost. Suggested measures include:
• Granting tenants and leaseholders the right to install home chargepoints
• Simplifying planning rules for domestic on-street chargers
• Expanding approval for safe crosspavement charging gullies
• Reforming network regulations to lower standing charges for public charge point operators.
of BEV registrations which were for models eligible for the electric car grant in Q2 and September. Image via New AutoMotive
These low-cost policy interventions could make EV ownership genuinely affordable for millions more drivers, while reducing the need for expensive purchase subsidies.
EARLY LESSONS AND NEXT STEPS
The first month’s data offers only an early snapshot of the ECG’s performance. New AutoMotive emphasises that further analysis over the coming quarters will be essential to determine whether consumer behaviour evolves as awareness of the grant spreads and as more eligible models reach showrooms.
For now, the key takeaway is clear: the Electric Car Grant is bolstering confidence rather than driving conversion. It demonstrates commitment, strengthens industry signalling, and keeps electric mobility in the headlines, but at a high fiscal cost and with uncertain long-term benefits.
As Farrar concludes, “We are running out of time to deliver the fair, effective suite of policy solutions required to accelerate the uptake of EVs. Structural changes to charging and access will do far more to open up the market than short-term grants ever could.”
Percentage
September’s most popular eligible battery electric models, by share of the BEV market. Image via New AutoMotive
Changes in BEV market share of ECGeligible models between Q2 2025 and September. Image via New AutoMotive
• -45 °C to +150 °C
• Efficient Heating and cooling
• Flow & pressure control
• Single/multiple fluid circuits
• Automated drain & refill
• Integrated pressure overlay
• Heat exchange pump option
Inspired by temperature
The Unimotive range is specially designed for applications in the automotive industry. Typical applications include temperature simulations as well as material testing and temperature-dependent stress and load tests for automotive parts and functional components.
www.huber-online.com
NEW: GREEN LINE models with natural refrigerant CO2
In traditional aircraft, thermal management systems must dissipate 3550kW of waste heat from onboard systems
ELECTRIFYING FLIGHT
Leading the charge in hybrid-electric aircraft thermal management
As aviation accelerates toward electrification, one of its biggest engineering hurdles isn’t thrust, it’s heat. Managing thermal loads in hybrid-electric propulsion systems is a defining challenge for sustainable flight. Addressing this head-on, Conflux Technology has joined the Honeywellled TheMa4HERA consortium - a major Clean Aviation initiative aimed at developing next-generation thermal management architectures for hybridelectric regional aircraft.
Announced in September 2025, the collaboration unites 28 partners across 10 European countries, coordinated from Honeywell Aerospace’s international development centre in Brno, Czech Republic. The project,
formally titled Thermal Management for Hybrid Electric Regional Aircraft (TheMa4HERA), focuses on new methods to handle the exponentially greater heat loads generated by hybridelectric propulsion compared with today’s conventional aircraft.
A GROWING HEAT CHALLENGE
In traditional regional aircraft, thermal management systems must dissipate roughly 35–50kW of waste heat from onboard systems. In the hybrid-electric configurations envisioned under Clean Aviation, that figure increases dramatically to between 20–50kW for systemlevel cooling and up to 1,000kW for energy storage and generation
components such as batteries, fuel cells, and auxiliary power units.
This order-of-magnitude increase in heat output demands a complete rethinking of thermal architecture, materials, and component design. Effective heat management is directly tied to system efficiency, weight reduction, and aircraft safety. Poor thermal control can degrade power electronics, shorten battery lifespan, and limit overall aircraft performance.
TheMa4HERA’s mission is therefore twofold: to innovate at the component level through developing advanced heat exchangers and cooling loops, and to validate new system-level architectures capable of efficiently distributing and rejecting heat in flight.
ADDITIVE ADVANTAGE
For Melbourne-based Conflux Technology, joining TheMa4HERA represents both an opportunity and a validation of its world-leading expertise in additively manufactured heat exchangers. Conflux has built a global reputation for designing compact, high-performance thermal components using metal additive manufacturing (AM), enabling intricate geometries and lightweight, integrated cooling solutions that conventional manufacturing cannot achieve.
Under TheMa4HERA, Conflux will contribute to several core work packages, including:
• Air Cycle Systems (ACS): Development of an air-to-air heat exchanger capable of managing dynamic temperature differentials under variable flight conditions
• Vapour Cycle Systems (VCS): Design and optimisation of air-toliquid heat exchangers serving as both evaporators and condensers within closed-loop systems
These innovations are expected to advance heat exchanger technology to Technology Readiness Level (TRL) 5 by 2026, supported by digital twin modelling, virtual demonstrations, and ground testing.
“Joining TheMa4HERA aligns perfectly with our mission to deliver high-performance thermal solutions that enable low-emission, energyefficient aviation,” says Michael Fuller, CEO of Conflux Technology. “Our additive manufacturing capabilities allow us to push the boundaries of design, achieving performance levels and weight savings critical to hybridelectric aircraft.”
CONSORTIIUM COLLABORATION
Honeywell’s leadership of the consortium reflects its long-standing expertise in aerospace thermal and environmental control systems, including air management, avionics cooling, and electric propulsion integration.
“Conflux brings valuable technological capabilities to TheMa4HERA’s collaborative effort to develop the next generation of thermal management solutions,” says Jan Ludvik, senior director of advanced technology Europe
TheMa4HERA aims to make hybrid-electric regional aircraft commercially viable within the next decade
at Honeywell Aerospace. “Each partner’s expertise strengthens our mission to deliver sustainable solutions that transform aviation.”
The consortium’s partners span the full ecosystem: OEMs, SMEs, universities and research institutes. This diversity enables cross-disciplinary innovation, combining aerothermal modelling, materials science, advanced manufacturing, and systems integration. By merging industrial experience with academic research, TheMa4HERA aims to generate a comprehensive set of validated design principles for scalable thermal systems.
The program’s Clean Aviation Phase 1 runs through 2026, focusing on subsystem and ground-based demonstration. Phase 2, beginning in 2027, will move toward flight testing and integration of the most promising designs in short- and medium-range hybrid-electric platforms.
ENGINEERING THE FUTURE OF SUSTAINABLE FLIGHT
Thermal management is foundational to achieving climate-neutral aviation by 2035, the central objective of the Clean Aviation programme. Without robust, lightweight, and efficient heat exchange systems, hybrid-electric and hydrogen-powered aircraft simply cannot operate reliably at scale.
Additive manufacturing brings a transformative advantage in this space. It enables complex internal geometries for enhanced heat transfer, reduced part counts, and integrated functionality, all of which contribute to lower weight and higher reliability. Moreover, the
digital workflow behind AM lends itself naturally to simulation-driven design, parametric optimisation, and digital twin validation, core methodologies within TheMa4HERA.
The consortium’s research also explores system-level optimisation, combining air cycle and vapour cycle systems into hybrid architectures capable of managing both cabin and propulsion cooling requirements. By integrating thermal loops, designers can reduce duplication of components and achieve higher overall energy efficiency.
TOWARD CLIMATENEUTRAL AVIATION
TheMa4HERA’s broader ambition is to make hybrid-electric regional aircraft commercially viable within the next decade. By demonstrating scalable, certifiable thermal management solutions, the project will help derisk the transition to new propulsion technologies - including batteryelectric, hydrogen, and fuel cell powertrains.
Beyond the technical outcomes, the project is fostering a collaborative industrial ecosystem that spans Europe and beyond. For Conflux, participation in TheMa4HERA not only positions it within the forefront of Clean Aviation but also opens pathways to future partnerships in zero-emission aerospace.
“Thermal management is the unseen enabler of electrified flight,” Fuller says. “Through advanced additive design and collaboration within TheMa4HERA, we’re building the foundations for the next generation of sustainable aircraft.”
TEST, SAFETY & SYSTEMS
The Voltt helps manufacturers avoid costly redesigns
REINVENTING CELL SELECTION
A newly-launched cloud platform is accelerating vehicle battery cell selection by up to six months
In battery system design, few decisions carry as much weight or risk as choosing the right cell.
The wrong choice can derail a programme’s cost, performance, and schedule before the first prototype leaves the bench. Yet despite the centrality of this decision, cell evaluation remains slow, fragmented, and heavily reliant on lengthy physical testing.
Now, About:Energy, a UK-based specialist in battery modelling and characterisation, is changing that with The Voltt - a cloud-based platform that promises to cut cell selection time by as much as six months, transforming one of the most complex bottlenecks in battery engineering into a streamlined, data-driven process.
A NEW PARADIGM FOR CELL EVALUATION
Battery cell selection underpins every major design decision in electrification
programmes, from range and charging speed to lifetime and thermal management. But engineering teams are often forced to make those decisions using incomplete or incomparable data, especially in the early design stages when prototype systems are unavailable.
“The Voltt is about transforming the economics of battery programmes for decision-makers,” explains Dr Gavin White, co-founder and CEO of About:Energy. “In aviation, for example, every kilogram of battery weight affects range, safety and cost. By giving leaders the evidence to choose the right cell at the outset, we’re empowering them to make decisions that unlock performance and commercial advantage without costly trial-and-error.”
Built on About:Energy’s validated model library, The Voltt is the first dedicated cell selection platform designed specifically for high-
performance battery development. It enables engineers to model, test, and compare multiple cells under realistic duty cycles in a browser, without the need for additional software.
The platform leverages a vast dataset derived from thousands of cells tested at the company’s Londonbased laboratory, representing the equivalent of centuries of testing data. With access to more than 30 highperformance cells from manufacturers such as Molicel, Amprius, EnpowerGreentech, and InoBat, engineers can simulate performance characteristics across use cases ranging from aerospace and drones to motorsport and high-power consumer systems.
FIRST-TIME RIGHT DESIGN
Traditionally, validating new cells can take months of iterative testing to understand behaviour under different load profiles, temperatures
The Voltt cell library and charging regimes. The Voltt compresses this process into weeks by offering digitally modelled, real-world performance simulations grounded in About:Energy’s proprietary data.
Using The Voltt, engineers can define mission profiles, such as an urban delivery cycle, endurance drone flight, or track racing scenario, and instantly assess how different cells perform in terms of energy density, voltage response, temperature rise, degradation, and cost impact. Crucially, this is not synthetic data. Each model in The Voltt’s library is derived from empirical testing and validated against real cells, ensuring predictive accuracy across various chemistries and form factors.
“Engineers are under huge pressure to make high-stakes choices quickly,” says Lorenzo Bergamaschi, product lead for The Voltt. “Often, they don’t yet have the full system-level data available at early design stages. The Voltt bridges that gap by giving them validated data and clear insight so they can evaluate options confidently and design better systems from the start.”
By enabling “first-time-right” cell decisions, The Voltt helps manufacturers avoid costly redesigns, reduce prototype cycles, and bring new electrified platforms to market faster, all while improving range, lifetime, and total cost of ownership. Early users across aerospace, UAVs,
space systems, and motorsport have already reported tangible gains, including up to six months’ reduction in cell selection time and significant confidence improvements in earlystage design decisions.
BUILT ON DEEP BATTERY INTELLIGENCE
At the core of The Voltt is About:Energy’s expanding database of battery behaviour. Over years of research, the company has characterised thousands of cells through extensive testing, capturing dynamic charge and discharge performance, thermal responses, and degradation pathways under diverse load conditions. This data forms the foundation of the company’s trusted digital cell models, used by OEMs and Tier-1 suppliers to feed into simulation environments or to drive real-time battery management optimisation.
The launch of The Voltt represents About:Energy’s strategic shift from providing bespoke data and consultancy to delivering scalable, cloud-based software tools for the broader engineering community.
VALIDATED IN THE FIELD
The Voltt has already demonstrated its value through collaborations with pioneering electrification companies.
A recent programme with Quantum Systems’ EFT drone division, for instance, used The Voltt’s simulation capabilities to de-risk early design decisions. Engineers were able to narrow down optimal cell candidates based on weight, thermal performance, and expected lifetime before physical prototypes were built, cutting months from the programme schedule.
In high-performance automotive and motorsport contexts, The Voltt’s real-time comparative tools enable engineers to visualise trade-offs between range, charging time, and degradation across multiple suppliers, supporting more resilient supply chain strategies as well as technical optimisation.
EMPOWERING THE NEXT GENERATION OF BATTERY ENGINEERS
About:Energy has grown by over 50% in the past year, attracting talent from Northvolt, Lilium and other leaders in advanced electrification. Looking ahead, the company plans to expand The Voltt’s coverage to include solidstate and lithium-sulfur chemistries, alongside enhanced API integration for simulation workflows. By providing a unified platform for data, modelling and decision support, The Voltt is aiming to become the industry’s definitive environment for early-stage battery evaluation.
COMPACT AUTOMATION
Compact, flexible and sustainable testing for the next generation of aviation systems
At a time when aerospace manufacturers and maintenance organisations are under intense pressure to deliver more with less – less time, less energy, and fewer resources – Spherea’s ATEC ATMOS represents a timely innovation. As the newest member of the established ATEC portfolio, this compact automatic test bench redefines the balance between performance, simplicity and sustainability in avionic and systems testing.
Unveiled at MRO Europe 2025 in London, ATEC ATMOS is designed to meet growing demand for lightweight, flexible, and connected test systems that can handle both production and maintenance requirements. By distilling Spherea’s three decades of test engineering expertise into a smaller, smarter, and more adaptable package, ATEC ATMOS offers manufacturers and MROs a new path toward efficient, future-proof testing operations.
PROVEN RELIABILITY
For more than thirty years, Spherea’s ATEC systems have been the backbone of avionics testing for both commercial and defence aerospace programmes. The first ATEC Series 6 benches, introduced in the early 1990s, remain supported today – evidence of the company’s long-term commitment to customers. The more recent ATEC Series 7 continues this legacy, and the arrival of ATEC ATMOS extends it further, guaranteeing 20 years of support from launch.
“Today, we are taking on a new challenge by building on our ATEC expertise: making things simpler, more compact, and more flexible for our customers,” says Olivier Sentier, head of product lines at Spherea. “ATMOS complements and streamlines the ATEC range without compromising the quality that has made it renowned. It’s about accessibility, agility, and continuity.”
DESIGNED FOR TODAY’S MRO AND PRODUCTION REALITIES
ATEC ATMOS is built around a generic test core, capable of supporting a wide range of electronic and electro-mechanical equipment with a reduced number of signals. Its modular architecture makes it equally suited to Production Acceptance Tests
The ATEC ATMOS automatic test bench
(PAT) and Return-to-Service (RTS) operations, handling everything from control panels and sensors to displays, data concentrators, radio components, and power electronics.
For MRO providers, the system’s small footprint, affordability, and low energy consumption make it ideal for workshops where space and efficiency are at a premium. For manufacturers, its openness and interoperability with existing hardware, software, and ATEC infrastructure ensure smooth integration into established production environments.
In practical terms, ATEC ATMOS offers users a complete, stand-alone platform for avionics and systems testing without requiring extensive customisation or proprietary add-ons. Its plug-and-play architecture allows operators to focus on test strategy rather than system setup, reducing development and operational costs.
SMART AND FLEXIBLE
Spherea describes ATEC ATMOS using four key attributes that define its design philosophy:
• +Small: Compact, accessible, and energy-efficient, ATMOS minimises physical and environmental footprint while offering the same level of precision as larger systems
• +Open: Compatible with major test software environments – TestStand, SMART, Visual, LabVIEW, C language, and ATLAS – as well as existing ATEC systems, ATMOS leverages COTS instrumentation to avoid vendor lock-in
• +Smart: An intuitive interface and integrated data exploitation tools simplify test development and improve productivity. Its built-in “MEMO” module turns test data into actionable insights, aiding both engineering and maintenance teams
• +Flex: Modular, scalable, and upgradeable, ATMOS evolves with user needs. Whether adding new test interfaces, connecting external instruments, or integrating cybersecurity functions, the system is designed to adapt over time
BUILT FOR THE CONNECTED TEST ENVIRONMENT
ATEC ATMOS is a connected test platform aligned with Industry 4.0
For MRO providers, the system’s small footprint, affordability, and low energy consumption make it ideal for workshops where space and efficiency are at a premium
principles. By integrating with the Spherea software suite, the system allows seamless data exchange and centralised supervision. This connectivity enables remote diagnostics, fleet-level performance tracking, and predictive maintenance analytics, helping operators make smarter decisions based on real test data.
Key integrated modules include:
• A cybersecurity drawer to protect sensitive test environments
• An energy consumption management module, supporting sustainability goals by optimising power usage
• A supervision module for real-time control and monitoring
These embedded features reflect Spherea’s wider commitment to sustainable, secure, and digitalised test operations, a growing priority in the aerospace sector.
OPTIMISING MRO EFFICIENCY AND LIFECYCLE COSTS
Maintenance operations face a dual challenge: reducing turnaround time while extending equipment lifespan. ATEC ATMOS directly supports both objectives. By automating repetitive procedures and standardising test sequences, the system eliminates manual steps that traditionally slow down troubleshooting and validation. The platform’s automation and repeatability ensure consistent, traceable results, reducing the likelihood of test errors while improving compliance with quality processes such as EN 9100. Moreover, ATMOS requires minimal maintenance itself.
Existing ATEC users benefit from
shared infrastructure across the product family: identical metrology instruments, common spare parts, and unified training frameworks. This approach streamlines logistics, minimises operational costs, and simplifies longterm maintenance planning.
LONGEVITY BY DESIGN
ATEC ATMOS aligns with Spherea’s broader sustainability vision. By optimising energy consumption, extending the service life of test assets, and offering compatibility across generations, the system reduces the need for frequent equipment replacement - an important lever for corporate social responsibility (CSR) and environmental stewardship.
Spherea’s obsolescence management and repair expertise ensure continuity of support for decades, allowing customers to safeguard their investments and comply with evolving product policies. ATEC ATMOS is the result of close collaboration between Spherea’s R&D teams and its network of customers: manufacturers, MROs, and global industrial players. This co-development process ensures that every feature of ATMOS addresses real operational needs rather than theoretical design targets.
By pooling elements from Spherea’s technology catalogue into a standardised, modular architecture, the company has created a test bench capable of serving diverse applications with unprecedented efficiency. The result is a single, universal solution that empowers aerospace professionals to configure, customise, and scale their test capabilities without compromise.
New air springs boost safety and durability for commercial fleets COMMERCIAL FLEET SAFETY
In response to increasing demands for reliability and uptime across the commercial vehicle sector, Monroe has launched a comprehensive new range of Magnum Air Springs engineered specifically for heavy-duty trucks, buses, and other commercial applications.
Designed with the same OE-grade precision that has made Monroe a trusted name in vehicle dynamics, the new air spring line introduces multiple design and material innovations aimed at improving ride stability, reducing component wear, and extending service life - all key benefits for fleet operators under pressure to lower total cost of ownership.
ENGINEERING FOR TOUGH ENVIRONMENTS
“Commercial vehicle air springs operate in a brutal environment that demands application-specific design enhancements, premium materials and high manufacturing standards,” says Sylvain Gary, senior product manager, EMEA, DRiV. “Monroe Magnum Air Springs are engineered and built for long-lasting performance and help keep vehicles safe in challenging conditions.”
Drawing on decades of experience as an original-equipment (OE) supplier, Monroe’s engineering team developed the new Magnum range with data-driven improvements validated through extensive durability and environmental testing. Each component is tailored to the operational profile of heavy commercial fleets, where long service intervals, high axle loads, and exposure to road contaminants can degrade standard suspension parts.
KEY TECHNICAL ENHANCEMENTS
At the heart of the new range are several design upgrades developed to extend operating life and improve fatigue resistance:
• Premium rubber bellows made from a proprietary blend of high-grade elastomers maintain flexibility over long service cycles
while resisting ozone, grit, and extreme weather
• A new bumper design, tested to withstand up to 89 kilonewtons (kN) of force without cracking, adds resilience during suspension compression events
• Application-specific pistons are offered in two configurations: ultra-high-strength steel pistons for heavy-duty, high-load vehicles, and lightweight plastic pistons featuring an advanced anticorrosion coating for reduced weight and improved longevity This modular approach ensures compatibility across a wide vehicle range, including Mercedes-Benz, DAF, MAN, Volvo, Renault Trucks, and IVECO, among others.
MULTIPLE APPLICATIONS
The Monroe Magnum portfolio covers three principal air spring architectures:
• Convoluted air springs, ideal for axle lifting systems in multi-axle trucks and for vibration isolation in industrial machinery
• Rollover air springs, designed to enhance lateral stability and maintain vehicle control during cornering or when carrying uneven loads
• Complete assembly air springs, available in both lightweight plastic and high-strength steel piston versions, optimised to maintain correct ride height and vehicle centre of gravity
By maintaining consistent ride height and damping road shocks, air springs
not only improve handling and safety but also protect other suspension components such as shocks and bushings from premature wear.
REDUCING DOWNTIME THROUGH RELIABILITY
Air spring failure is a leading cause of unscheduled downtime in heavyduty fleets, often resulting in costly roadside repairs or service delays. The Monroe Magnum range addresses this with components engineered for reliability under extreme duty cycles.
“Distributors and service providers can help customers eliminate premature failures and other costly issues by offering air springs that have been engineered for reliability and durability – all from Monroe, a brand they know and trust,” adds Gary.
NEW CHAPTER IN HEAVY-DUTY SUSPENSION
While Monroe is best known globally for its shock absorbers and ride control systems, the move into air springs represents a strategic expansion of its commercial vehicle offering under DRiV, the Tenneco business group focused on aftermarket innovation. DRiV supports fleets and workshops with a portfolio that includes Monroe, MOOG, Walker, and other well-known brands, delivering OE-quality replacement parts that enhance vehicle performance, comfort, and uptime.
The Monroe Magnum Air Spring range is now available across Europe and other global markets through DRiV’s established distribution channels.
The new range of Magnum Air Springs
3D Smart Sensors
• Many high-speed, high-resolution, wide field of view model options
• Factory calibrated for out-of-the-box measurement
• 3D shape (height) and 2D intensity (contrast) data
• Onboard inspection software with built-in measurement tools
• Multi-sensor networking support for maximum scan coverage and cost efficiency
AUTONOMOUS TRAIN TECH
European startup Futurail has closed a €7.5 million funding round to advance the development and certification of its autonomy stack for self-driving trains, marking a key milestone in the digital transformation of rail mobility. The round was co-led by Asterion Ventures (Paris) and Leap435 (Munich), joined by EIT Urban Mobility and US investors Zero Infinity Partners and Heroic Ventures.
Founded in 2023, Futurail operates between Strasbourg and Munich, bringing together veterans from Tesla, Argo AI, and Edge Case Research – the same engineering talent that helped pioneer autonomous driving in the automotive industry. The company’s mission is to apply this expertise to rail, making trains not only safer and more efficient, but also more attractive as the backbone of low-carbon transportation.
“While leading the Autopilot team at Tesla, I saw how autonomy can completely transform an industry,” says Alex Haag, CEO and co-founder of Futurail. “We founded Futurail to bring that same potential to rail –turning a 200-year-old system into a core enabler of sustainable mobility.”
ENGINEERING THE FIRST CERTIFIED DRIVERLESS TRAIN SYSTEM
At the heart of Futurail’s innovation is FUTURAILDriver, an AI-based autonomy stack that can be integrated into new rolling stock or retrofitted to existing fleets. The system combines perception, decision-making, and control layers, allowing trains to detect and respond to obstacles, signals, and other operational events in real time.
FUTURAILDriver is being developed to meet European safety and certification standards, with the company targeting Technology Readiness Level (TRL) 6–7 and initial certification for autonomous depot operations - a key early use case that
New funding is helping to advance the development of self-driving trains
enables safe, repeatable manoeuvres without human intervention.
Beyond depots, the system is designed to support higher levels of automation on mainline and regional networks. Futurail’s goal is to tackle one of the sector’s most pressing challenges: the shortage of qualified train drivers. Automating core operational functions can allow operators to run more services at lower cost, reopen unprofitable secondary lines, and increase network capacity without major infrastructure changes.
“Autonomy unlocks both growth and efficiency,” explains Maximilian Schöffer, CCO and co-founder.
“Operators can run more trains, more often, at lower cost – that’s a gamechanger for the entire industry.”
INDUSTRY IMPACT
Futurail has already established partnerships with major industrial players. In Europe, it is collaborating with Lohr Group, known for its advanced transport systems, and in the US with Parallel Systems, a startup founded by former SpaceX engineers developing automated, battery-electric freight vehicles. These alliances give Futurail a foothold across both passenger and freight markets, two domains poised to benefit from increased automation. At scale, the company estimates its systems could shift
millions of passengers and tonnes of freight from road to rail, avoiding more than 10 million tonnes of CO2 emissions annually.
According to Dr Patrick Dendorfer, CTO and co-founder, “This isn’t a research project – it’s about delivering a certified, safe system that can redefine how people and goods move. We’re building real technology for deployment, not experimentation.”
EUROPE’S NEXT ERA OF RAIL INNOVATION
Investors view Futurail as a key player in the emerging autonomous rail ecosystem, with the potential to position Europe at the forefront of smart, sustainable transport.
“Just as electric traction replaced steam, autonomy is the transformative technology of this century for rail,” says Dr Matthias Kempf, founding partner at Leap435. “Futurail is delivering that leap and ensuring Europe’s industry stays ahead.”
With its new capital, Futurail will expand its engineering and operations teams, advance pilot projects with major OEMs and operators, and push toward regulatory approval and commercial trials.
By blending AI-driven autonomy with the reliability of rail, Futurail is not only addressing a structural labour challenge but also paving the way for a new era of efficient, connected, and climate-friendly transport.
Futurail has already established partnerships with major industrial players
asc-sensors.de
ANALOG • DIGITAL • SMART
The evolution in sensor technology
At ASC, we are your partner for monitoring and optimizing driving dynamics. Our tailormade high-precision inertial sensor and IMU solutions help maximize the efficiency of your vehicles, keep passengers and freight safe and your business productive.
Our compact yet robust analog, digital and smart sensors, paired with the expertise of resourceful engineers, offer a flexible range of tools to test and track, predict and maintain vehicle conditions in every imaginable real-world setting.
Testing of cars, trucks, utility vehicles and motorcycles requires inertial sensors with high resolution as well as a robust and compact design. In addition to the capability of measuring very low frequencies and amplitudes, they must be resistant to vibrations and shocks, while taking up small installation space. Both accelerometers and gyroscopes, as well as inertial measurement units (IMUs) from ASC perfectly fulfil these demanding requirements.
Fatigue Strength Test & Test Drives
ADAS Road Load Data Analysis
Machine vision and AI have a role to play in error detection and real-time monitoring
QUALITY 4.0
Simon Francis, group quality director at G&P, introduces the concept of Quality 4.0 and explores ways to effectively adopt digital quality management practices across transport manufacturing
The manufacturing industry is undergoing a period of transformation, driven by the integration of advanced digital technologies into quality management systems - a development increasingly referred to as “Quality 4.0”. Building upon the foundations of Industry 4.0, which introduced AI, the Internet of Things, machine learning, and data-driven automation into production environments, Quality 4.0 is helping redefine the role of quality in modern manufacturing.
GUIDING PRINCIPLES
With integrated digital systems deeply embedded in manufacturing and global supply chains, the potential for systemic failure has increased, as has the stakes of getting it wrong. One single error
in a network of interconnected digitised systems can cascade across procurement, logistics and production, resulting in catastrophic failure and widespread disruption that ultimately increases waste, the cost of production and can reduce customer confidence. Therefore, the focus of quality requires a transition toward embedding resilience, governance and continuous improvement into the digital backbone of organisations.
This vision is echoed among quality leaders and is underpinned by the Chartered Quality Institute (CQI), which has outlined eight principles that define Quality 4.0: mutual trust; rapid adaptive learning; transparency and collaboration; cyber-physical systems; technology and combined intelligence; data value; cybernetics and co-creation of value; provide a robust framework for
quality in the new digital age. These principles serve as practical tools to guide manufacturers through the transition to intelligent, automated systems without losing sight of the fundamental role of people, purpose, and value creation.
AVOIDING TECH FOR ITS OWN SAKE
Technology must be implemented with purpose and intention because those introduced without a clear rationale can add complexity rather than clarity. Effective future quality systems must therefore prioritise simplicity, accuracy and utility. The role of the future quality function will be to ensure that technology investments are adding value to assurance and governance rather than following trend-driven enthusiasm. Questions around need,
Simon Francis, group quality director at G&P
Quality 4.0 does not seek to replace people but to integrate human capability with digital tools
cost, accuracy, ease of training and time-to-deploy should become standard considerations before introducing AI or automation into inspection and decision-making processes.
However, it’s just as important to consider the value of human expertise. In the context of inspection activities, while machine vision and AI have a role to play in error detection and real-time monitoring, the simple fact is that people remain essential in scenarios requiring judgement or physical adaptability. For example, short-term projects with fast set up requirements or products that present in an inconsistent form may not warrant the technological and learning time investment.
Thus, Quality 4.0 does not seek to replace people but to integrate human capability with digital tools. Finding the right balance is essential for a digital Quality Management System (QMS) to be effective.
A SYSTEMS-WIDE APPROACH
Manufacturers should take a holistic view of their quality systems. Quality 4.0 demands transparency and alignment across the entire value chain, with OEMs, tiered suppliers,
logistics providers and production units increasingly encouraged to adopt compatible technologies, share data and align on quality objectives. Such transparency can reduce duplication, strengthen traceability and enable earlier detection of risks. As such, quality professionals are more and more being asked to advise on digital strategy, data governance and risk control at a systemic level.
Organisations like G&P Quality Management are already adapting to meet these needs. With in-house technical specialists, cross-sectoral expertise and a deep understanding of quality assurance, we’re evolving from traditional analogue inspection service providers into consultative partners. Through end-to-end audits, risk mapping and process design, we help manufacturers identify where digital tools can most effectively be deployed, whether through AIpowered control systems or humanled simplification initiatives.
FACILITATING THE TRANSITION
Without practical implementation and adoption strategies, there is a risk that Quality 4.0 becomes aspirational rather than actionable. To bridge this gap, businesses
must invest in upskilling their workforce, build internal capability for evaluating technology and align digital initiatives with core business objectives. Leadership, change management, training and governance are just as important as the technology itself.
The future of manufacturing will be defined by both the technologies adopted and the wisdom with which they are applied. Quality 4.0 represents an opportunity to shift quality from a control function to a catalyst for innovation and proactive control. If approached correctly, it promises greater consistency, fewer failures and more sustainable, valuedriven operations. However, the benefits can only be fully realised if organisations resist the temptation to adopt technology for its own sakeinstead focusing on enabling systems that are intelligent, resilient, and above all, fit for purpose.
In the end, the question is whether quality professionals and organisations are prepared to adopt and shape Quality 4.0 wisely. With the right combination of foresight, governance and technical acumen, the principles of Quality 4.0 can become the new cornerstone of innovation and assurance for decades to come.
Quality 4.0 can guide manufacturers through the transition to intelligent, automated systems
TOUGH TESTING
Multi-talented sensor for commercial vehicle testing under tough conditions
ASC’s capacitive accelerometers help optimise vehicle dynamics
Commercial vehicles for heavy use are typically put through their paces and adapted to conditions in their intended areas of operation. Like those from a leading global manufacturer based in Germany, who has been leveraging ASC sensor technology for nearly two decades. Whether on the test track, on test benches or in real-world use: ASC’s capacitive accelerometers help optimise vehicle dynamics, component design, material selection and damping measures, as well as the overall operational stability and service life of commercial vehicles.
SIMULATING GLOBAL OPERATING CONDITIONS
“Apt sensor technology plays an essential role in accurate load detection for the tuning and quality control of our vehicles”, states one of the ASC clients’ test engineers with over 15 years of experience in the field of operational stability. Each vehicle
prototype undergoes a rigorous testing programme. “It starts on our test track for measuring vibration behaviours. Here we can simulate a wide variety of conditions to reflect those around the world.”
The vehicle is driven over a wide range of diverse road types, surfaces and conditions. This includes inclines, declines, curves and obstacles such as speed bumps, railroad crossings with interlocking tracks, potholes, cobblestones or wet and slippery road sections. These sequences of obstacles and manoeuvres are analysed and evaluated for maximum permissible stress loads.
Vibration loads are recorded at critical points across the vehicle. The aim is both to check whether the actual loads are within the scope of calculations and to obtain reference data for subsequent operational load reproduction tests on the test bench. Facilitating this, inertial sensors from ASC record exact accelerations and directions, rotational movements,
maximum speeds and reversal points. From that, further relevant forces and complex mechanical stress loads are calculated, which the components get exposed to intensively on the test bench later, over extended periods of time.
ASC 5525MF: THE ALL-ROUNDER
“The sensors we use must be extremely robust and versatile”, states the engineer. Triaxial capacitive accelerometers of the ASC 5525MF (Medium Frequency) range lend themselves specially to this. With measuring ranges from ±2 to ±200g and a wide frequency response from 0 to 7kHz (±3 dB), they are particularly suitable for capturing low and medium frequencies.
As typical driving manoeuvres such as accelerating, braking, coupling, negotiating bends, overcoming long bumps, railroad crossings, thresholds, curbs or dips and much more often require measuring ranges up to a
Each vehicle prototype undergoes a rigorous testing programme
It starts on our test track for measuring vibration behaviours. Here we can simulate a wide variety of conditions to reflect those around the world
maximum of 100Hz. “Without the ability to accurately capture low frequency responses, we wouldn’t be able to replicate real-world conditions and loads during test drives.”
The robust ASC 5525MF design ensures strong resistance to repeated shock loads of up to 6,000g. It comes embedded in a reliable stainless-steel housing of protection class IP 67. All this and its flexible installation options make the analogue accelerometer ideal for accurate data acquisition under highly variable, sometimes unexpected and adverse terrain, environmental and climatic conditions.
FINE-TUNING WITH CAPACITIVE MEASUREMENT TECHNOLOGY
After the test drives have been completed, the commercial vehicles undergo a second round of thorough testing on test benches. To simulate continuous loads over their entire service life, they get “shaken” for
weeks on servo-hydraulic test rigs that replicate those movements and loads as closely as possible that will impact the vehicle in real-world use.
“In so-called operational load reproduction tests, innovative sensors are used to replicate the actual operating profile”, explains the head of the manufacturer’s measurement and calibration laboratory. “The overall stress on individual components and the entire vehicle then gets extrapolated from these test series to thousands of additional miles.” Which saves the producer a lot of time and wear, personnel, fuel and other material costs.
These reproduction tests can take up to 400 hours or more, in automated 24/7 mode. Based on the insights, the material strength of critical components is optimised and the effectiveness of suitable measures to reduce the impact of stress and increase service life – such as vibration damping measures – gets evaluated and adjusted.
INERTIAL SENSORS OF PRECISION AND STABILITY
The accurate measurement of linear acceleration is critical for the valid recording and evaluation of stress events. “We need precise accelerometers that are also easy to handle and install”, says the measurement expert. “They must cover wide frequency ranges, be robust and deliver stable results over the long term. Water, dust or dirt must not affect these sensors.”
ASC 5525MF triaxial accelerometers are particularly suited for these intensive testing series. Their compact design facilitates quick installation and removal – a fundamental advantage in NVH (noise, vibration, harshness) and test bench applications.
Based on proven MEMS technology and the capacitive measurement principle, they enable the detection of even the smallest acceleration forces in three degrees of freedom across a wide frequency response. This ensures maximum accuracy and stable longterm results. ASC 5525MF sensors are, therefore, popular for use in test settings, vehicle and road surface monitoring, yet also in resonance and vibration tests in aviation, for another example.
Words by Oliver Stohlman on behalf of ASC Sensors.
The ASC 5525MF accelerometer
SAFEGUARDING AGAINST SWITCHING SURGES
Unveiling a new range of compact automotive surge-protection Zener diodes for next-generation vehicle electronics
Toshiba Electronics Europe has expanded its range of automotive-grade surgeprotection Zener diodes with the introduction of the XCEZ series, a family of ultra-compact devices designed to safeguard vehicle electronics from electrical noise, switching surges, and electrostatic discharge (ESD).
Housed in a miniaturised SOD523 package, the new diodes enable high-density mounting in today’s increasingly compact electronic control units (ECUs). Their small footprint — just 1.6mm x 0.8mm — represents a 59% reduction in mounting area compared with the SOD-323 package used for Toshiba’s previous XCUZ series. This makes the XCEZ family particularly well-suited for space-constrained automotive systems such as in-vehicle infotainment (IVI), advanced driverassistance systems (ADAS), and battery management systems (BMS).
NOISE AND SURGE PROTECTION FOR THE ELECTRIFIED ERA
As vehicle electrification and connectivity advance, automotive ECUs are increasingly exposed to electrical noise and transient surges. These disturbances, ranging from nanosecond-scale ESD events to millisecond-scale switching surges, can induce malfunctions or even potentially permanent damage to sensitive circuitry.
The XCEZ series addresses these vulnerabilities by providing a robust suppression path for transient energy, diverting harmful surges away from vulnerable ICs and signal lines. This protection is essential for maintaining system stability and reliability, especially in applications handling high-speed communication or precision sensing.
ADVANCED PROCESSES FOR LOW DYNAMIC RESISTANCE
At the core of the XCEZ family lies Toshiba’s proprietary Zener diode process, optimised for low dynamic resistance (RDYN) – a key parameter determining how effectively a diode absorbs surge energy.
A lower dynamic resistance allows surge current to flow more easily through the diode, thereby clamping voltage spikes faster and more efficiently. For example, the XCEZ5V6 variant achieves a typical RDYN of only 0.16Ω, significantly reducing residual voltage during transient events and improving protection for downstream components.
This low resistance also enhances the diode’s capability to handle longer surge durations. The XCEZ devices can dissipate up to 6W (10ms pulse width), offering reliable protection against switching surges and near-DC overvoltages – conditions increasingly common in electrified powertrains and high-current control modules.
COMPREHENSIVE LINEUP AND AUTOMOTIVE-GRADE RELIABILITY
The XCEZ series comprises 20 part numbers, covering Zener voltages from 5.6V to 36V. This broad range allows designers to select optimal
protection levels for major power supply lines and signal interfaces across diverse ECU architectures. Every device in the lineup is fully AEC-Q101 qualified, ensuring compliance with stringent automotive reliability standards. This qualification confirms the diodes’ durability under thermal cycling, mechanical shock, and humidity conditions typical of the automotive environment.
ENABLING COMPACT RELIABLE AUTOMOTIVE ELECTRONICS
By combining high surge-absorption performance, miniaturised packaging, and automotive-grade reliability, Toshiba’s XCEZ series helps engineers design smaller, lighter, and more robust electronic systems.
For developers of next-generation ADAS, EV battery systems, and infotainment platforms, these new diodes simplify PCB layout, reduce footprint, and enhance resilience against the increasingly harsh electrical environment of modern vehicles.
As the automotive industry continues its transition toward electrified and software-defined architectures, components like the XCEZ series play a vital role in ensuring that the underlying electronics remain stable, noiseimmune, and reliable, even under demanding operating conditions.
The Toshiba XCEZ series
SUPERIOR SILICONE
Wevo has launched a high-performance 2K silicone adhesive for thermal management in EV batteries and power electronics
Wevo has introduced Wevosil 28015 FL, a new two-component (2K) addition-curing silicone adhesive that combines high thermal conductivity, mechanical strength, and residual flexibility – a unique performance blend tailored for electric vehicle (EV) batteries and power electronics. The new material represents a significant step forward in structural bonding and thermal management for next-generation mobility systems.
BALANCING THERMAL AND MECHANICAL PERFORMANCE
Modern electric drivetrains and power electronics operate at increasing power densities, making thermal control a key design challenge. Conventional gap fillers and pastes provide good heat transfer but lack structural integrity, often requiring additional fasteners or mechanical supports. Wevo’s new adhesive bridges this gap by offering thermal conductivity of 1.5W/m·K, while maintaining the strength of a structural bonding material.
Tested according to DIN EN ISO 22007-2:2015-12 (hot-disk method), the material effectively conducts heat away from components, preventing thermal hotspots that can degrade performance or reduce service life. Simultaneously, a Shore A hardness of 70 and modulus of elasticity of 60N/mm2 ensure a mechanically stable bond even under structural
loads – a crucial advantage for battery modules that serve as load-bearing components in modern vehicle architectures.
Despite its stiffness, Wevosil 28015 FL retains an elongation at break of 20–25%, providing sufficient flexibility to accommodate differential thermal expansion between bonded materials and to mitigate stress-induced cracking during temperature cycling.
DESIGNED FOR PROCESS EFFICIENCY
The new 2K RTV silicone is thixotropic, making it suitable for bead dispensing from standard cartridges, hobbocks, or drums. It supports both CIPG (Cured-In-Place Gasket) and FIPG (Formed-In-Place Gasket) applications, giving manufacturers flexibility in automated assembly.
Fast curing further enhances productivity. When exposed to infrared (IR) or laser radiation, the adhesive achieves initial adhesion exceeding 2MPa within minutes, significantly shortening cycle times. This rapid cure behaviour enables seamless integration into automated production lines for EV battery modules or power electronics housings. The addition-curing mechanism prevents volumetric shrinkage and gap formation, ensuring reliable bonding even in closed assemblies or complex geometries.
APPLICATIONS IN EV BATTERIES
In battery systems, Wevosil 28015 FL
supports structural bonding of modules to their housings, while maintaining a thermal connection to cooling systems or bodywork heat exchangers. This dual function enhances both mechanical stability and heat dissipation, contributing to improved crash safety and operational efficiency under extreme temperature fluctuations.
For power electronics, the adhesive offers a robust alternative to traditional thermal interface materials. By combining mechanical rigidity with high thermal transfer, it eliminates the need for additional fasteners or layered constructions, simplifying assembly and improving long-term reliability of inverters, converters, and control units operating under continuous thermal cycling.
SUPPORTING INNOVATION IN THERMAL MANAGEMENT
With Wevosil 28015 FL, Wevo continues to expand its portfolio of customised silicone systems for the automotive and electronics sectors. The company’s focus on combining thermal, mechanical, and processing performance reflects a growing demand for multifunctional materials that enable efficient, lightweight, and reliable component design.
As EV platforms evolve toward higher power and tighter packaging, materials like Wevosil 28015 FL are poised to become key enablers of safer, more efficient, and more durable energy systems.
Wevosil 28015 FL
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AUTONOMOUS TRANSFORMATION
Rounding up the latest training and upskilling initiatives from across the transport sector
The transport industry is experiencing a rapid technological evolution, fuelled by innovation in automation, electrification, and artificial intelligence. To keep pace, leading institutions and industry bodies across the globe are investing heavily in education and workforce development. Recent announcements from Curtin University, the UK’s automotive training sector, and the National Franchised Dealers Association (NFDA) highlight a coordinated effort to equip workers with the skills needed for a smarter, cleaner, and more autonomous transport future.
AUSTRALIA’S AUTONOMOUS FUTURE
Curtin University has announced a new strategic partnership with Greenroom Robotics, one of Australia’s leading maritime autonomy companies. The collaboration is designed to strengthen national capabilities in autonomous systems, artificial intelligence (AI), and
innovation—key pillars underpinning Australia’s future transport and defence sectors.
The partnership will focus on developing a framework to accelerate research, workforce skills, and industry partnerships across multiple sectors, including maritime, energy, space, mining, and agriculture. Greenroom Robotics, renowned for its advanced situational awareness and AI software, already supports partners across AUKUS nations - such as Austal, the Royal Australian Navy, and UK-based SubSea Craft - and has completed successful trials with the US Department of Defense.
Gary Hale, Director of Curtin’s National Resilience and Security Program Office, said the collaboration reflects Curtin’s ongoing commitment to real-world impact.
“By combining Curtin’s leading research expertise with Greenroom’s advanced robotics and autonomy capabilities, this partnership aims to deliver best-in-class solutions to
enhance Australia’s resilience and support national priorities,” Hale explains. “It will help build a highly skilled talent pipeline, accelerate the adoption of next-generation autonomous systems, and deliver innovation that strengthens Australia as a nation.”
For Greenroom Robotics, the partnership provides access to Curtin’s research ecosystem and a new pathway to expand its influence in AI-enabled autonomy. COO and co-founder Harry Hubbert said, “We are thrilled to contribute our expertise in cutting-edge maritime AI and autonomy software to Curtin’s collaborative ecosystem. Our proven solutions are already transforming maritime autonomy, and we’re excited to access a broader partner base to make a real difference to safe, clean, and protected oceans.”
Together, the two organisations are laying the groundwork for a new era in autonomous systems education and research which aims to not only bolster Australia’s sovereign capability
Recent DAF apprentice graduation ceremony. Image via SMMT
but also prepare the next generation of engineers, data scientists, and robotics specialists.
TRANSFORMING HEAVY VEHICLE TRAINING
Across the globe, the UK is experiencing a similar transformation, particularly in the heavy vehicle and automotive sectors. This year has seen record investment in technical training facilities, with new academies opening in Derby, Manchester, Nottingham, Sheffield, and Warwick. These centres are designed to deliver advanced training for technicians, equipping them with the expertise to service both traditional diesel vehicles and emerging technologies such as electric and hydrogen-powered trucks. The expansion of training academies comes amid growing demand for skilled technicians and engineers capable of supporting the transition to cleaner transport. Industry leaders recognise that upskilling today’s workforce is vital to maintaining safety,
reliability, and performance as new technologies enter the market.
Recent graduation ceremonies have highlighted the scale of this progress, with more than 120 heavy vehicle technician and parts apprentices celebrated at one of the largest industry events to date. These achievements underline the value of long-term investment in technical education, both for individual career growth and for the sector’s competitiveness.
However, industry stakeholders emphasise that continued government support is essential. Following recent departmental reshuffles, the Society of Motor Manufacturers and Traders (SMMT) is calling for alignment between the Department for Education (which oversees under-19 education) and the Department for Work and Pensions (responsible for adult training). Collaboration between these departments is key to addressing the full lifecycle of workforce development, from school leavers to mid-career professionals seeking to reskill.
The UK is already facing a shortage of qualified EV technicians, which could present a major obstacle to the nation’s zero-emission goals
SMMT’s joint STEM Returners Project, developed with the aerospace sector, is one example of how the industry is encouraging diversity and inclusion by welcoming career changers and returners. With skills needs spanning electric and hydrogen propulsion to autonomous technologies, opening pathways to people from all backgrounds is seen as essential to long-term success.
SUPPORTING THE NEXT GENERATION
The National Franchised Dealers Association (NFDA) is also pushing for reform in technical education to meet the challenges of the zeroemission transition. The NFDA has urged the UK government to ensure the automotive industry is fully represented in the development of new V-level qualifications for 16-year-olds - a replacement for existing Level 3 BTecs and other similar courses.
Designed to sit alongside A-levels, T-levels, and apprenticeships, V-levels will offer a more flexible, employment-focused route into technical careers. The NFDA believes these qualifications could be pivotal in addressing the UK’s acute shortage of electric vehicle (EV) technicians, a gap that poses a potential obstacle to achieving national net-zero goals.
Sue Robinson, NFDA chief executive, said the new qualifications could help inspire a new generation to pursue careers in automotive technology.
“The UK is already facing a shortage of qualified EV technicians, which could present a major obstacle to the nation’s zero-emission goals,” Robinson warns.
“We urge the Department for Education to include the automotive sector within the first wave of V-level development and to work closely with industry to design qualifications that address this growing skills gap.”
Through its Drive My Career initiative, the NFDA continues to engage employers and young people to promote opportunities in automotive retail, service, and repair. By ensuring the sector’s inclusion in the new qualification framework, the NFDA hopes to build a steady pipeline of skilled professionals ready to power the transition to electrified and connected mobility.
Curtin University has announced a new strategic partnership with Greenroom Robotics
TAKE A HOLISTIC APPROACH TO THE VEHICLE: LEARN NEW & INTELLIGENT WAYS TO DEVELOP & INTEGRATE LATEST CHASSIS TECHNOLOGY, CONTROL COST & INCREASE VEHICLE PERFORMANCE #CHASSISSYSTEMSEU25 Join Leading OEM & Tier 1 Brands: Code ITN100 for €100 Off! enquire@automotive-iq.com
18TH - 20TH NOVEMBER, 2025 | BERLIN, GERMANY
3 Razor-Focused, Simultaneous Conferences Across Braking / Steering / Suspension: Join 100+ Global Leaders.
ADVANCING INTERATED VEHICLE TECHNOLOGIES
As the automotive industry navigates unprecedented economic and technological shifts, OEMs are demanding more practical, realworld development and integration of vehicle systems. The 17th Annual Automotive Chassis Systems Europe 2025 conference will address these challenges head-on, showcasing intelligent ways to advance chassis technology, control costs, and enhance vehicle performance.
With vehicle innovation cycles now halving from five to just two years, the sector is rapidly evolving towards integrated chassis systems and holistic vehicle motion control. The rise of electrification and increasing levels of autonomy are accelerating this transformation, bringing both opportunity and complexity. Yet, cost pressures remain a key barrier,
making cost-effective engineering and smart integration strategies central themes of this year’s event.
The conference offers three focused streams – Braking Systems, Steering Systems, and Suspension Systemsspanning three full days of technical content, discussions, and networking. Attendees will gain actionable insights from 50+ expert speakers representing major OEMs and Tier 1 suppliers,
DRIVING THE FUTURE OF THE AUTOMOTIVE AFTERMARKET
From 9–11 December 2025, the Dubai World Trade Centre will once again host Automechanika Dubai, the Middle East and Africa’s largest international trade show for the automotive aftermarket. Bringing together over 2,400 exhibitors from more than 60 countries and 20 international pavilions, the 22nd edition promises to be the most comprehensive yet, covering every aspect of the industry across 10 key product sectors – from Parts & Components and Electrics & Electronics to Diagnostics & Repair, Tyres & Batteries and the new Connectivity & Autonomous Driving area.
The three-day event will be a global hub for networking, learning, and innovation, featuring live product demonstrations, technical discussions, and expert-led conferences exploring the latest trends shaping the aftermarket ecosystem. Attendees will gain insights into emerging technologies, sustainability, and digital transformation while connecting with key decision-makers from across the MEA region.
A highlight of the show, the Automechanika Dubai Awards 2025, will take place on 10 December, celebrating excellence, innovation,
including ZF Group, Volkswagen, Toyota, Bosch, Magna, Mercedes-AMG, Ford, and Hyundai.
With 100+ global attendees and a dedicated exhibition area, participants will have the chance to explore cutting-edge systems, technologies, and solutions shaping the future of chassis design and integration.
From cost innovation to nextgeneration vehicle motion control, Automotive Chassis Systems Europe 2025 is the must-attend event for engineers, developers, and decisionmakers driving the next phase of vehicle performance and safety.
For more information visit: www.automotive-iq.com/eventsautomotive-chassis-systemseurope
and leadership across the sector. Two new categories - Rising Star in Automotive Aftermarket and Distributor of the Year - will debut, recognising the next generation of industry leaders and outstanding regional distributors.
With its unmatched scale and focus on future-ready solutions, Automechanika Dubai 2025 offers a powerful platform to explore growth opportunities, forge partnerships, and experience firsthand how the automotive aftermarket continues to evolve in an era of electrification, automation, and sustainability.
Automechanika Dubai will take place 9–11 December 2025
Automotive Chassis Systems Europe 2024
INNOVATION, INTEGRATION AND GLOBAL COLLABORATION
From 26–29 November 2025, the National Exhibition and Convention Centre (Shanghai) will host Automechanika Shanghai 2025, one of the world’s largest automotive trade fairs and a major global hub for innovation, collaboration, and market expansion.
Spanning 383,000 sqm and featuring more than 7,000 exhibitors from 43 countries and regions, this year’s edition marks the event’s largest and most international showcase to date.
Automechanika Shanghai 2025 will bring together 15 overseas pavilions and four domestic clusters, highlighting the full spectrum of
the global automotive value chain. International participation has surged by nearly 20%, with strong representation from Germany, Italy, Korea, Thailand, Turkey, the UK, and the US, reflecting the show’s growing influence as a platform for crossborder partnerships.
Key highlights include the debut of several regional pavilions spotlighting China’s thriving new energy vehicle (NEV) and intelligent mobility sectors. Exhibitors from industrial hubs such as Changzhou, Hubei, Longquan, and Tianjin will showcase cutting-edge solutions in electric powertrains, intelligent chassis systems, thermal
management, and vehicle connectivity.
In addition to its extensive exhibition, the event will feature over 90 fringe programmes, including forums, product launches, and technical seminars that foster dialogue on sustainability, digitalisation, and the future of mobility.
According to Fiona Chiew, general manager of Messe Frankfurt, “Automechanika Shanghai’s global perspective and focus on emerging trends make it a key meeting point for international trade, innovation, and collaboration.”
For four days, Shanghai will once again become the epicentre of the global automotive aftermarket.
Automechanika Shanghai 2025 will bring together 15 overseas pavilions and four domestic clusters
10 YEARS OF FORMNEXT
At Formnext, international market leaders present their latest developments all along the process chain in Additive Manufacturing: from high-performance materials and precision system technology to automated post-processing and integrated software and quality assurance solutions.
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AVIATION LOGISTICS NETWORK
The Aviation Logistics Network provides 24/7 logistics support to the Aviation Industry. We ensure commercial aircraft continue to fly via the co-ordination and delivery of components, spare parts, engines etc. into the supply chain and maintenance bases.
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KRYTOXTM PERFORMANCE LUBRICANTS
From spacecraft to harsh manufacturing conditions, Krytox™ performance lubricants thrive on tough challenges in the most unforgiving environments in a wide array of industries.
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HILLIARD
Hilliard offers a diversified product line for industrial applications in a wide variety of industries. Hilliard products are designed, manufactured and sold according to our customers' applications.
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KLUBER LUBRICATION
Klüber Lubrication is one of the world's leading manufacturers of speciality lubricants offering high performance solutions to virtually all industries and markets worldwide..
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TEFLONTM FLUOROPOLYMERS
Experience unmatched versatility and performance. TeflonTM fluoroplymers deliver superior chemical and themal resistance, optimizing automotive performance and unlocking innovation.
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tesa®
For more than 125 years, tesa® has remained as one of the world’s leading manufacturers of industrial adhesive tapes for a broad range of sectors and applications, improving the work, products and lives of customers
