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.
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NEW: GREEN LINE models with natural refrigerant CO2
Welcome
The electrification of the transport sector continues to evolve at a remarkable pace, with technological innovation, infrastructure expansion, and policy momentum converging to reshape how we move people and goods. As such, we at International Transport Manufacturer have decided that this transition deserves more of our attention. From this issue onwards, we will focus wholly on electric in line with this industry shift.
You can expect more from us on new battery technologies (page 6) battery inspection (page 26) and battery safety (page 24), as well as more comprehensive coverage of charging technologies (page 18) and infrastructure developments (page 22). We will also hone our coverage of hybrid technologies and vehicles (page 10), diving deep into the world of BEVs, PHEVs, FCEVs. And our coverage will not be limited to the road, as we aim to root out the latest technological advances in electrification across the aviation, rail (page 34) and marine sectors, too. All in all, you can expect a lot of exciting things to come from us over the coming issues, and we’d love for you to join us on this journey. So, if you’ve got news to share, an exciting product to shout about, or an opinion to get off your chest - do reach out to us.
As always, our regular Skills Zone feature (page 40) rounds up the latest training and upskilling opportunities from across the transport sector, while our Show Preview section highlights the must-visit industry events of the next quarter from page 43.
Hayley Everett Editor
– AUGUST 2025 –
Lithium-ion leap
The role of data in the rail sector’s shift from lead-acid to lithium-ion batteries
POWER TRAIN
10
Hybrid propulsion
Combining combustion, electrification and transmission technologies for next-gen low-emission vehicles
MATERIALS
13
Elastomer excellence
How smart material engineering can solve elastomer gasket failures
16
Recalibrating the graphene narrative Andrew McInnis shares
Paragraf’s latest technical breakthrough in electronics manufacturing
18 Megawatt goes the mile
Rounding up the latest developments in megawatt charging technology
22 Charging forward
Jake Holmes assesses the current state-of-play within the UK’s EV charging infrastructure TEST, SAFETY & SYSTEMS
24 Layered approach to lithium-ion
Protecting energy storage systems from the effects of thermal runaway 26 Driving battery quality
How industrial CT and automation are transforming EV battery manufacturing
30 Trail mix
This new modular toolkit is making life easier for commercial vehicle trailer manufacturers
32
Building trust
How can companies learn to trust AI within battery R&D?
PUBLISHER
Jerry Ramsdale
EDITOR
Hayley Everett heverett@setform.com
STAFF WRITER
Jake Holmes jholmes@setform.com
DESIGN – Dan Bennett, Jill Harris
HEAD OF PRODUCTION
Luke Wikner production@setform.com
BUSINESS MANAGERS
John Abey | Darren Ringer
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Paul Maher, Iain Fletcher, Peter King, Marina Grant
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CONTACT US...
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34 Sensing change
Diving into the latest sensor technology advances within the rail sector 36
Door to door
How inertial sensors are improving the performance of delivery van doors SKILLS ZONE 40 Reshaping the transport sector
Rounding up the latest training and upskilling initiatives across the transport industry SHOW PREVIEW
43 Industrial AM in the spotlight
Formnext returns to Frankfurt in November 44
Powering the future of mobility
Move America takes place in Detroit in September
Setform’s international magazine for transport is published twice 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.
Umesh Patel, business director at ODOS, discusses the critical role of data in the rail industry’s shift from lead-acid to lithium-ion batteries
Advanced data logging tools created by ODOS are essential for capturing high-frequency performance metrics in modern lithium-ionequipped rail systems, enabling predictive maintenance and improved safety
The transition from lead-acid to lithium-ion batteries in rail applications represents a significant advancement for the industry. While lithium-ion technology offers clear benefits - such as increased efficiency, longevity, and sustainability - understanding its full-scale performance is essential to ensuring optimal operation. Realworld collaborations, such as recent trials with leading developers like AMP Rail, have highlighted the crucial role that real-time data plays in supporting this shift. Data is crucial for assessing battery health, efficiency and longevity. The longer lifespan of lithium-ion batteries presents new challenges and without precise, real-time data, operators cannot fully understand performance boundaries. Rail operators need detailed insights into how these batteries function under real-world conditions; without this knowledge, they won’t be able to identify inefficiencies or resolve potential failures before they escalate.
UNDERSTANDING THE SHIFT
For decades, rail operators have relied on lead-acid batteries to start diesel engines and power auxiliary systems. However, these batteries come with significant limitations, including short lifespans, lower energy density, and environmental concerns. Lithium-ion technology is emerging as a superior alternative due to its lighter weight, longer cycle life, and higher energy efficiency. Although they have a higher initial cost, they offer long-term savings by reducing maintenance needs and extending replacement intervals. However, the adoption of this technology without a comprehensive understanding of its real-world performance could lead to operational disruptions. This is where data logging becomes crucial.
TRANSITION CHALLENGES
One of the key challenges in transitioning to lithium-ion batteries is ensuring consistency in their performance. Variability between battery batches can present issues when deployed in the rail industry, where equipment operates under highly demanding conditions. Unlike
Legacy locomotives are being upgraded with lithium-ion battery systems, but their performance must be verified with precise, real-world data to ensure reliability under extreme conditions
consumer products, rail assets are in near-constant use, maximising uptime but also placing significant stress on the batteries.
These stresses are amplified by environmental extremes - lithiumion systems must operate reliably in climates ranging from sub-zero arctic mornings to desert heat exceeding 50°C. Additionally, safety remains a core concern. The potential for thermal runaway and overheating means that detailed, real-world performance data is essential for both validating safety and ensuring resilience under pressure. Without this data, operators risk relying on assumption-led diagnostics, leading to avoidable battery swaps, inefficient maintenance cycles, and increased costs.
THE ROLE OF DATA
Data logging technology will play a pivotal role in supporting rail operators by providing real-time insights into battery performance. By monitoring key parameters such as battery degradation, charge cycles, voltage stability, and energy usage, rail operators can optimise fleet performance while reducing diagnostic times. Real-world implementations have demonstrated that with the right data, critical failures in harsh environmental conditions can be completely avoided, improving both safety and confidence in lithium-ion systems.
This shift to data-driven maintenance enables early fault detection, extends battery life, and reduces the need for
manual inspections. Such outcomes not only prevent costly failures but also support long-term investment strategies by informing predictive maintenance schedules. As lithium-ion adoption accelerates, this kind of visibility is essential to overcome both technical uncertainty and legacy infrastructure limitations.
OVERCOMING THERMAL CHALLENGES
One of the primary concerns in rail applications is environmental exposure. Depending on where the data logger is installed, it could be exposed to elements such as water, dust, and extreme temperatures. This is particularly relevant in commercial trains, where frequent door operations expose components to external conditions. Additionally, trains operate at high speeds and are subject to constant vibration, which can be detrimental to electronic components, particularly those with moving parts. A data logger designed for this environment must be ruggedised to withstand such forces
without degradation.
Thermal management is equally critical. Lithium-ion batteries generate significant heat during operation, necessitating integrated cooling solutions to ensure consistent performance and prevent failure. In proven rail trials, realtime logging of temperature patterns and current draw has been instrumental in mitigating risks such as thermal runaway. These systems must also have robust processing and storage capacity to manage high-frequency data capture across a broad temperature spectrum.
LESSONS FROM AUTOMOTIVE
Industries that rely on highperformance battery technology, such as automotive and aerospace, have long understood the value of real-time data tracking. A luxury sports car manufacturer, for example, used data logging to detect unauthorised vehicle use before it even reached the test track. Similarly, in rail applications, detailed monitoring ensures that improper battery usage, inefficiencies, or degradation do not go unnoticed,
safeguarding both assets and operational performance.
DATA MANAGEMENT IS KEY
The transition from lead-acid to lithium-ion batteries in rail applications offers substantial technical, environmental, and operational benefits. Lithium-ion batteries provide longer life cycles, faster charging and higher energy density, while data logging and remote monitoring systems help optimise performance, reduce downtime and improve safety. By utilising cloudbased technology like ODOS’ solutions, rail operators can track real-time data, identify potential issues early and make informed decisions about their investments in new technology. As the rail industry continues to embrace lithium-ion technology, the key to success lies in proper testing, training, and data management. With the right systems in place, rail operators can maximise the benefits of lithiumion batteries, ensuring efficient, reliable, and cost-effective operations for the long term.
As the rail industry continues to embrace lithium-ion technology, the key to success lies in proper testing, training, and data management
ODOS’ megalog data logger
DRIVING LITHIUM-ION ADOPTION
AMP Rail, a specialist in lithium-ion power systems for locomotives and industrial equipment, partnered with ODOS as part of its mission to meet the increasingly demanding energy and safety requirements of modern rail fleets.
The objective of the partnership was primarily to enable deep, real-time visibility into lithium-ion battery performance under the extreme and variable conditions faced by rail vehicles, and in doing so, accelerate industrywide adoption of this cleaner, more efficient technology. AMP Rail recognised that data transparency is essential not only to mitigate the risks of lithium-ion batteries, but to also build trust around new technologies. To truly validate lithium-ion as a safe and scalable solution, the company needed to detect early failure indicators, prove performance across environmental extremes, and provide engineers with actionable insights in real time.
DATA SYSTEM DEPLOYMENT
To meet these needs, ODOS deployed its advanced monitoring and analytics platform across a pilot fleet of lithium-ion-equipped locomotives. Each battery system was fitted with embedded smart sensors and rugged data loggers capable of capturing key metrics including temperature, voltage, current draw, charge/discharge cycles, and degradation trends.
This data was streamed in real time to ODOS’s secure cloud-based platform, where engineers could monitor system health via a custom-built dashboard. This enabled early detection of failure risks and thermal irregularities and continuous verification of safe operation in extreme temperatures. This also allowed for automated diagnostic routines, reducing the need for manual inspection, and data archiving to support safety certification and regulatory compliance.
The platform was specifically tailored to AMP Rail’s operational protocols, with alerts and reporting tools integrated directly into existing maintenance workflows. This minimised the need for retraining and allowed for seamless adoption across depots and engineering teams.
INDUSTRY IMPACT
The results of the pilot were conclusive. AMP Rail recorded a dramatic reduction in diagnostic time for batteryrelated faults, zero critical failures under extreme thermal conditions, and notable fuel savings through smarter charge and idle management. Predictive maintenance, powered by real-time data, also contributed to longer battery life and more efficient resource allocation.
Perhaps most significantly, the data-driven approach helped reshape industry perception. By enabling transparent monitoring and proving resilience under field conditions, AMP Rail accelerated lithium-ion adoption among industry partners by an estimated five to 10 years.
As David Eldridge, AMP Rail’s lead on the project, notes: “The more data we have, the more confident the industry becomes in making the transition to lithium-ion. ODOS has been instrumental in giving us and our customers confidence. The system has removed the guesswork, and we’re already seeing the impact in reduced downtime and higher operational reliability.”
As rail operators strive to decarbonise and modernise, lithium-ion technology presents a compelling alternative to legacy systems. Yet trust, underpinned by real-world performance data, remains essential. The partnership between AMP Rail and ODOS demonstrates how embedded diagnostics and intelligent analytics can enable not just technology adoption, but also a broader shift in mindset, where safety, efficiency, and sustainability go hand in hand.
ODOS’ CloudSoft cloud-based data logging tool
The HR18 HEV provides a flexible, high-performance platform that can be easily implemented across multiple vehicle architectures
The HR18 HEV powertrain platform
HYBRID PROPULSION
How one company is combining combustion, electrification, and transmission technologies to provide a scalable platform for next-generation low-emission vehicles
Horse Powertrain, through its Horse Technologies division, has unveiled a fully integrated hybrid powertrain platform – the HR18 HEV. Representing a significant step forward in hybrid vehicle architecture, the HR18 HEV is the company’s first complete propulsion system to be designed, developed, and manufactured entirely in-house. It brings together an Atkinson-cycle internal combustion engine, a highefficiency lithium-ion battery, a clutchless gearbox, and a high-torque electric motor – all engineered by
Horse Technologies’ own R&D centres and produced across its European manufacturing sites.
This launch reinforces Horse Powertrain’s strategy to support automotive OEMs with scalable hybrid systems at a time when HEVs are becoming central to many brands’ low-emission line-ups.
FULLY INTEGRATED HYBRID STRUCTURE
The HR18 HEV sets a new benchmark in hybrid integration by consolidating all major powertrain elements –combustion, electrification, and
transmission – into a cohesive, modular package. The result is a platform optimised for hybrid operation, with seamless interaction between each component and a clear focus on performance, efficiency, and emissions compliance.
The system is built around the all-new HR18 engine, a 1.8-litre, fourcylinder petrol direct injection unit. Designed for hybrid applications, the HR18 maximises thermal efficiency, achieving up to 80kW (108 PS) and 172Nm of torque, while maintaining a low weight of just 100kg. It is compatible with flex-fuel blends
containing up to 10% ethanol and fully compliant with both Euro 6e (Euro 6EBIS) and Euro 7 emissions regulations.
Power is transmitted via Horse Technologies’ newly developed DB45S transmission, a clutchless gearbox capable of handling up to 436Nm of torque. Manufactured in Seville, Spain, the DB45S eliminates traditional clutch mechanisms, enhancing reliability and efficiency while reducing mechanical complexity.
The electric propulsion is managed by the 5DH motor, a 50kW permanent magnet electric motor that delivers peak torque of 212Nm. Engineered and produced in Aveiro, Portugal, the 5DH motor is optimised for smooth operation in hybrid driving conditions and contributes significantly to overall system efficiency and responsiveness.
Energy storage is provided by the BTA Gen2 lithium-ion battery, designed and developed at Horse’s Valladolid R&D centre. Compact and lightweight at 36kg, it stores up to 1.4kWh of
energy, operates across a voltage range of 150–279V, and delivers a peak discharge of 11.6Ah. Despite its small footprint (707 x 422 x 190mm), the battery pack integrates two 34-cell modules and an active liquid cooling system, ensuring consistent thermal performance across varied duty cycles.
ENGINEERING INTEGRATION ACROSS EUROPE
The HR18 HEV system is the product of a coordinated European R&D and manufacturing effort. The combustion engine was developed at Horse Technologies’ Bucharest R&D centre in Romania, with production – including casting, machining and assembly –taking place at its plants in Valladolid (Spain) and Bursa (Turkey).
Meanwhile, the battery, motor, and transmission were each developed and manufactured at specialised centres in Valladolid, Aveiro, and Seville respectively. This decentralised but integrated approach enables Horse Powertrain to leverage local engineering expertise, streamline logistics, and reduce time-to-market for OEM customers.
SUPPORTING OEMS AMID MARKET TRANSITION
The HR18 HEV addresses several critical pain points facing vehicle manufacturers as they navigate the transition to electrified mobility. With hybrid vehicles increasingly seen as a pragmatic bridge between internal combustion and full battery-electric platforms, OEMs are under pressure to deploy HEV offerings quickly and at scale – often under significant commercial constraints.
Matias Giannini, CEO of Horse Powertrain, explains: “The HR18 HEV is designed directly to address challenges facing OEMs in today’s market. HEVs are becoming the most in-demand powertrain category in many markets, requiring many brands and OEMs to make significant investments in bolstering their HEV offering – all while they face unprecedented commercial pressures.”
By delivering a fully integrated hybrid powertrain, Horse Powertrain offers OEMs a turnkey solution that reduces the need for complex
system integration, costly validation processes, and long development timelines. The HR18 HEV provides a flexible, high-performance platform that can be easily implemented across multiple vehicle architectures, allowing automakers to focus their R&D resources on differentiation and user-facing technologies.
SCALABLE PATH TO DECARBONISATION
The HR18 HEV is not only a technical achievement but also a strategic product for accelerating the industry’s decarbonisation goals. Designed to serve global markets, the system supports manufacturers in meeting tightening emissions targets without full reliance on batteryelectric vehicle (BEV) infrastructure or supply chains.
Patrice Haettel, CEO of Horse Technologies, notes: “The HR18 HEV is the culmination of work by teams across Horse Technologies’ European network of plants and R&D centres. It further strengthens our transition into a fully integrated powertrain partner for the automotive industry and reflects our team’s unwavering commitment to delivering a complete range of propulsion solutions.”
This launch aligns with broader efforts to create accessible, highefficiency propulsion systems that bridge current internal combustion technologies and the long-term shift to electrification. As an adaptable hybrid platform, the HR18 HEV provides an immediate, implementable pathway for OEMs looking to cut emissions, meet evolving legislation, and improve vehicle efficiency.
With the HR18 HEV, Horse Powertrain has delivered a sophisticated and modular hybrid powertrain tailored to the evolving needs of today’s automotive market. Developed entirely in-house and backed by a coordinated European manufacturing footprint, the system positions Horse as a critical enabler of next-generation mobility. Its efficient integration of combustion, electrification, and mechanical systems provides a timely and technically robust option for OEMs pursuing hybrid solutions in a rapidly changing regulatory and consumer landscape.
ELASTOMER EXCELLENCE
Randi
Claire Villeda-Lindsay discusses how smart material engineering can solve elastomer gasket failures
In complex mechanical systems –especially those in the automotive sector – seemingly minor components can cause major problems when they fail. Elastomer gaskets, for example, play a vital role in sealing fluid systems, yet they’re often overlooked until something goes wrong.
A recent case study from a US-based sealing distributor highlights how unexpected chemical incompatibility can disrupt performance, and how collaboration, reverse engineering, and smart material selection can provide
a long-term solution for OEMs facing similar challenges.
THE PROBLEM
According to the case study, a longterm client in the transportation industry began experiencing premature failures in a custommoulded elastomer gasket. The gaskets were part of a mobile unit’s cooling system and had been performing reliably until failures started surfacing in the field, leading to leaks, downtime, and costly warranty claims.
The issue was complex and difficult to isolate. Initial investigations showed that the gasket material was compatible with the coolant it was sealing. So, what went wrong?
DISCOVERING THE ROOT CAUSE
After a detailed engineering review, the failure mechanism was uncovered. The issue wasn’t with coolant compatibility at all. It turned out that oil exposure during routine maintenance – specifically during oil changes – was contacting the gasket and degrading the material. The material, while suitable for coolant, wasn’t chemically resistant to oil.
This is a common oversight in sealing design; assuming that because a seal functions well with the primary fluid, it will also withstand incidental contact with others. In real-world applications, fluid contamination happens more often than many engineers expect, especially in shared environments like powertrain systems.
Elastomer gaskets play a vital role in sealing automotive fluid systems
The custom elastomer gasket
THE SOLUTION: DUAL COMPATIBILITY
Once the issue was identified, the team working on the automotive seal project partnered with one of their top elastomer suppliers to source a more chemically resilient material. The new gasket would need to resist both engine oil and coolant, and meet requirements for temperature extremes, pressure cycles, long-term durability, and manufacturability for high volumes.
The material selection phase involved lab testing and side-by-side comparisons of various compounds, evaluating their compatibility with both fluids as well as mechanical performance under simulated operating conditions. The ability to access advanced testing capabilities through supplier partnerships helped expedite this phase significantly.
REVERSE ENGINEERING
Interestingly, no formal drawing existed for the original gasket. The engineering team had to reverse engineer the component, creating a new design from the physical sample. Once the client approved the dimensional drawing, the tooling department got to work on a new mould for the replacement part. Reverse engineering is often necessary for legacy or custom parts, especially when technical documentation is missing. It requires careful measurement and validation, but it also presents an opportunity to improve the design with updated materials and processes, especially when scaling up for high-volume production.
In this case, reverse engineering helped replicate the original geometry and allowed the team to fine-tune tolerances and incorporate subtle design enhancements based on field experience.
PROOF IN PERFORMANCE
Before scaling up to production, the team produced first article samples for real-world testing. These were evaluated for thermal stability, oil and coolant resistance, and dimensional integrity over time.
The outcome was promising. The samples not only passed, but exceeded,
the performance thresholds set by the original design. With this validation in place, production moved forward. According to the case study, the new gaskets have been in the field for over a year without a single warranty claim. This represents both major cost savings for the client and reflects improved reliability for their end-users. This example shows how a custom sealing solution - backed by good engineering and materials science - can make a tangible difference in product performance and brand reputation.
The new gaskets have been in the field for over a year without a single warranty claim
LOOKING AT THE LESSONS
This case provides several insights for anyone working with seals in demanding environments. First, crosscompatibility matters. Even limited of incidental fluid exposure can degrade materials over time, engineers must always consider the full spectrum of potential contact points. Second, reverse engineering can be a powerful
The
tool. When drawings aren’t available, it’s still possible to recreate and improve upon a legacy part. Third, partnering with material experts can accelerate the development of solutions; the team’s ability to consult directly with advanced elastomer manufacturers made the process faster and more reliable. And last, testing before production saves costs later on. First article samples help to validate performance before OEMs commit to volume production.
GASKETS ARE SMALL, BUT CRITICAL
As automotive systems grow more complex, the materials used in even the smallest components need to perform in increasingly harsh and variable conditions. This case study serves as a valuable reminder that good sealing is not just about the shape of a part, but also about choosing the right material for realworld conditions.
It also highlights how forwardthinking engineering teams are going beyond troubleshooting to create proactive solutions that improve long-term system reliability. Strategic supplier collaboration, data-driven testing, and an openness to re-engineering legacy parts can dramatically shift outcomes for OEMs operating at scale.
team had to reverse engineer the gasket component
Custom Elastomer Testing
Paragraf’s GHS offer a powerful solution for diverse sensing applications. Image
RECALIBRATING THE GRAPHENE NARRATIVE
Andrew McInnis, chief development officer at Paragraf, shares the company’s latest technical breakthrough in electronics manufacturing
More than 20 years after the groundbreaking discovery of graphene by Andre Geim and Konstantin Novoselov at the University of Manchester, the “wonder material” continues to hold vast potential across multiple industries. Yet, despite early optimism, especially in electronics, graphene’s commercial adoption has lagged behind the initial hype.
In a recent technical talk at The Advanced Materials Show, Andrew McInnis, chief development officer at Paragraf, a UK-based company headquartered near Cambridge, sought to reframe this narrative and demonstrate how Paragraf’s innovations in scalable, electronics-grade graphene production are now unlocking the material’s long-promised potential across a wide range of industries, including electric vehicles (EVs).
“We don’t make metric tons of graphene,” he said. “We’re not chasing bulk composites. We’re addressing the electronics sector and solving the engineering problem of how to deploy graphene at scale with precision.”
UNDERSTANDING GRAPHENE
To contextualise the discussion, McInnis provided a brief overview of graphene’s structure. Graphene is a single atomic layer of carbon atoms arranged in a hexagonal lattice, peeled from graphite. It possesses superior properties: optically transparent, chemically inert, stronger than diamond, and most notably, highly conductive.
“Graphene is derived from graphite. It’s the only thermodynamically stable element in the sp2 hybridised form,” McInnis explained. “Take a single layer of graphite, and you get a material more strongly bonded than diamond, with unmatched electrical and mechanical properties.”
These exceptional properties stem from graphene’s unique band structure. First theorised by P R Wallace in 1947 while studying nuclear reactions, the linear dispersion relationship between energy and momentum - where the valence and conduction bands meet at a Dirac point - predicted extraordinary carrier mobility.
“Electrons in graphene behave more like waves than particles. They move at velocities approaching those of photons; an order of magnitude beyond any other semiconductor,” McInnis said.
BRIDGING SCIENCE AND ENGINEERING
Theoretical perfection, however, does not guarantee practical application. Real-world deployment introduces unavoidable imperfections. Graphene must be placed onto a substrate and encapsulated for device integration. At every stage - exposure to air, contact with polymers, or transfer between materials - its properties degrade.
“The race isn’t just about making graphene,” McInnis emphasised. “It’s about preserving its integrity through scalable engineering processes.”
Traditional methods like chemical vapour deposition (CVD) on copper foils followed by transfer to silicon introduce contamination, wrinkles, and defects. Other methods such as exfoliation or reduction of graphene oxide lack the reproducibility and
via Paragraf
Take a single layer of graphite, and you get a material more strongly bonded than diamond, with unmatched electrical and mechanical properties
quality required for electronic devices.
This is where Paragraf’s approach distinguishes itself. Rather than transferring graphene, the company grows single-layer graphene directly on electronic-grade substrates such as sapphire or silicon carbide using proprietary plasma-enhanced CVD techniques.
“We grow directly onto the enduse substrate. No transfer, no gaps, no multilayers - just a continuous, defect-minimised graphene film ready for device fabrication,” McInnis explained. “This is what allows us to deliver electronic-grade graphene at commercial scale.”
FROM MATERIAL TO PRODUCT
With robust control over material quality, Paragraf has focused on two core product categories: Hall effect sensors and graphene-based field effect transistors (GFETs) for molecular sensing.
Hall sensors benefit from graphene’s high carrier mobility, which allows for ultra-low-power operation and high sensitivity across a range of applications, from electric vehicles to cryogenic sensing in quantum computing.
“We’re already shipping sensors into markets that require precise, low-noise magnetic field detection at temperatures approaching absolute zero,” McInnis said. “That’s only possible because graphene remains
functional in such extreme conditions.”
GFETs, on the other hand, use the ambient environment - gas, fluid, or solid - as the gate input, making them ideal for biosensing and molecular diagnostics. Paragraf is developing sensors capable of detecting biomarkers in breath, such as acetone for diabetic ketoacidosis, or in liquid samples for early-stage medical diagnostics.
“These devices operate at incredibly high transconductance. A small change in molecular charge on the surface translates to a significant electrical response. That’s what gives us singlemolecule sensitivity,” said McInnis.
EV APPLICATIONS
In addition to quantum computing and medical diagnostics, Paragraf’s graphene-based Hall effect sensors are proving highly applicable to battery management systems (BMS) in EVs. Precise current sensing is critical for monitoring charge and discharge cycles, detecting cell imbalances, and ensuring thermal and electrical safety. Graphene’s ultra-high electron mobility enables low-noise, high-resolution measurements at extremely low power levels, making it ideal for continuous monitoring in energy-sensitive environments.
“With graphene, we can detect subtle current excursions that signal early battery degradation or potential failure,” said McInnis. “This supports predictive maintenance strategies and extends battery life, which is essential
for improving EV performance and reducing operational costs.”
Furthermore, the sensors maintain stability across a wide temperature range, a key requirement in EV applications where systems operate from sub-zero climates to intense summer heat.
ENGINEERING MATURITY
Beyond its producing capabilities, Paragraf is positioning itself as a foundry partner for the wider industry. It has implemented standard semiconductor quality control and statistical process control to bridge the gap between lab-scale innovation and industrial production.
“This is no longer just scientific exploration. It’s now an engineering discipline,” McInnis said. “We’ve moved from intuition-driven discovery to statistically reproducible device fabrication on wafer-scale platforms.”
The company recently transitioned into a new purpose-built facility in Huntingdon to support wafer-scale manufacturing and meet the volume demands of customers in automotive, aerospace, quantum computing, and medical diagnostics.
“We don’t intend to be the endproduct supplier forever,” said McInnis. “Our goal is to enable our partnersOEMs, fabs, and device companies - to incorporate 2D materials into their own systems. We are building a graphene foundry for the electronics industry.”
Probes test the current flow through a cryogenic GHS at low temperature. Image via Paragraf
MEGAWATT GOES THE MILE
The race to electrify long-haul transport is intensifying. Here, we look at the latest developments in megawatt charging technology and what these tell us about the future of heavy-duty electrification
The launch of BYD’s all-liquid-cooled Megawatt Flash Charging Terminal system
As electric vehicle (EV) adoption accelerates across Europe and Asia, the spotlight is now on a critical bottleneck in the transition to zero-emission freight: high-capacity charging for heavy-duty vehicles.
A new generation of megawatt-scale charging systems (MCS) is being piloted, commercialised, and deployed across regions to address the unique demands of electric trucks and buses. From EU-funded research projects and pan-European charging corridors to groundbreaking technology platforms in China, the latest developments indicate that megawatt charging is no longer a future aspiration but an emerging commercial reality.
BUILDING THE BACKBONE OF EUROPE’S TRUCK CHARGING NETWORK
One of the most significant initiatives in this space is the €10 million MACBETH (Multipoint megAwatt Charging for Battery Electric Truck Hubs) project, backed by the European Commission and coordinated by VTT Technical Research Centre of Finland. With participation from 19 industrial and academic partners, MACBETH is focused on building the technological and infrastructural foundation for a continent-wide MCS network to support battery-electric heavy-duty transport. Running through to 2029, MACBETH aims to validate highpower, multipoint charging through two full-scale demonstration hubs. These stations will simultaneously accommodate heavy-duty trucks, medium-duty vehicles, and even private electric cars. VTT senior scientist and project coordinator Yancho Todorov confirmed that one of the project’s key objectives is to trial new business models for depot and public charging infrastructure to ensure commercial viability.
One innovative component under evaluation is a robotic charging arm developed by Rocsys, designed to automate the high-power charging process. As Joost van der Weijde of Rocsys explains, “The robotised charging arm will not only free drivers’ time and increase productivity but also enhance safety. Currently, drivers must exit their vehicles, handle
Scania launched its MCS rapid charging solution at EVS38
heavy charging cables, and interrupt their break time. By automating the charging process, we’re addressing critical ergonomic, operational, and safety challenges.”
THE CORRIDOR STRATEGY
Complementing the MACBETH project is the rollout of Europe’s first megawatt-enabled freight corridor by Milence, a joint venture between Daimler Truck, the TRATON Group, and Volvo Group. The latest milestone in this effort was the expansion of Milence’s Landvetter charging hub near Gothenburg, Sweden, where a MCS is now operational.
The Landvetter site adds to Milence’s growing list of active hubs - currently four in Sweden and others in the Netherlands and Belgiumforming a strategic MCS corridor from the Port of Antwerp-Bruges to Stockholm. With the installation of Power Electronics’ MCS units delivering up to 1,440kW (1,000V, 1,500A), trucks like the Volvo FH Aero Electric can charge from 20% to 80% in 30–45 minutes, aligning with EUmandated rest breaks for drivers.
Anja van Niersen, CEO of Milence, emphasises that, “public charging infrastructure is the key enabler for
long-haul electric transport, and its success depends on high-power charging solutions deployed where demand is emerging fastest.” This corridor-first deployment model is central to the group’s strategy and aligns with the EU’s Alternative Fuels Infrastructure Regulation (AFIR), which mandates 600kW-capable stations every 60km on core transport routes by 2027.
COLD-WEATHER CHARGING
Megawatt charging is also being tested in one of Europe’s most challenging environments. German hardware manufacturer Autel Europe and Icelandic charge point operator ON Power have successfully deployed a commercial MCS site in Borgarnes, located on Iceland’s national Ring Road. The MaxiCharger MCS system currently offers 640kW but is built on a modular architecture designed to scale up to 1.2MW and 1,500A, fully compliant with IEC 61851 and ISO 15118 standards.
According to ON Power’s Jóhann Ingi Magnússon, “Our goal is to lead the energy transition and build infrastructure that supports emerging technologies - even before they reach mainstream use in Iceland.” Engineered
for extreme cold, this installation marks a technological milestone and underlines the viability of megawatt charging in harsh conditions.
COMMERCIAL CHARGING DEPLOYMENT
Truckmaker Scania, part of the TRATON Group, is preparing for fullscale commercial deployment of its own MCS-compatible electric trucks by early 2026. Scania’s MCS will support up to 750kW charging and a
The MCS technology allows both public and private charging infrastructure to meet the demands of high-capacity charging
Europe’s first MaxiCharger Megawatt Charging System
maximum current of 3,000A - twice the rate of today’s CCS2 standard. Charging a heavy truck from 20% to 80% will take less than 30 minutes, according to the company.
Daniel Schulze, head of Scania eTruck Solutions, highlights both performance and operational efficiency benefits: “Our new charging technology not only ensures operational efficiency and reliability over long distances but also supports our goal of making sustainable transport a practical reality.”
Traton Charging Solutions, the group’s dedicated e-mobility service provider, is simultaneously working to ensure that this ultra-fast charging is economically viable. Petra Sundström, managing director of Traton Charging Solutions, says: “The MCS technology allows both public and private charging infrastructure to meet the demands of high-capacity charging, ensuring that operators can recharge quickly and economically.”
A MATTER OF SECONDS
While much of the European focus is on heavy-duty vehicle infrastructure, China’s BYD has made headlines by introducing megawatt charging for passenger vehicles. The company’s Super e-Platform, launched in March this year, is built on a full-domain
Milence is close to completing Europe’s first MCS corridor
1000V architecture and integrates a 1MW (1000A, 1000V) “Flash Charging Battery.” According to BYD, this technology allows EVs like the Han L to gain 400km of range in just five minutes.
Chairman Wang Chuanfu summarised the company’s ambition: “The ultimate solution is to make charging as quick as refuelling a gasoline car.”
Supporting this high-speed charging is a new generation of self-developed SiC power chips, rated at 1,500V, and the world’s first liquid-cooled charging terminal capable of 1,360kW. BYD also plans to roll out 4,000 “Megawatt Flash Charging” stations across China, backed by dual-gun and voltageboosting technology for interoperability with existing infrastructure.
GRID CONSTRAINTS
Despite significant progress in megawatt charging technologies, challenges remain. According to the International Energy Agency, ultrafast chargers (150kW and above) accounted for nearly 10% of all public fast chargers by mid-2024, with
deployment growing by over 50% that year. However, grid congestion remains a significant barrier, particularly in regions such as the UK and the Netherlands, where planning delays and local grid limitations hinder deployment.
New EU legislation is attempting to resolve these bottlenecks. The AFIR regulation requires each highway station to deliver a minimum of 400kW by 2025, rising to 600kW by 2027. Still, achieving these targets will demand not only new hardware but also intelligent load management, public-private partnerships, and regulatory streamlining.
AN INDUSTRY CATALYST?
As heavy-duty EVs become more prevalent, the deployment of megawatt-scale charging infrastructure is emerging as a cornerstone of the decarbonised transport ecosystem. Projects like MACBETH are laying the groundwork for long-term network design and business viability. At the same time, manufacturers like Scania and BYD
Yancho
Todorov, senior scientist at VTT, and coordinator of the MACBETH project at VTT’s heavy-duty automotive lab
are proving that high-capacity charging is no longer limited to the laboratory or test track.
The transition to megawatt charging marks more than a technical evolution, but also demonstrates a fundamental rethinking of how energy is delivered, used, and monetised in the mobility sector. With strategic corridors opening up and commercial vehicles entering the market, the shift to high-speed, high-power electric charging is well underway.
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CHARGING FORWARD
Jake Holmes
assesses the current state-of-play within the UK’s electric vehicle charging infrastructure
Electric vehicles (EVs) offer an attractive solution to the growing climate crisis and air pollution concerns in densely populated areas, hence many governments’ increasing appetite to ramp up adoption.
But are we ready? Switching from traditional internal combustion engine (ICE) vehicles to EVs requires a large-scale change in infrastructure. Conventional fuel stations have been well-established for decades; altering these in line with the growing uptake of EVs will require both funding and social norm changes.
Sceptics do not believe the UK’s national electricity grid is ready for the switch, nor do they believe in everyone having their own charging station as a practical reality. Roger Brereto of Pailton Engineering is on hand to put some of these qualms to rest, however, as he looks into the lessons from abroad, the current state of UK infrastructure and what must happen next to close the charging gap.
GRID CONCERNS
Where EV buses have been deployed, local depots have required enhanced power connections to manage the increased electricity load. Highcapacity DC chargers for electric buses typically range between 300 and 600kW, normally requiring substantial upgrades to local grid infrastructure.
This change in power requires cooperation between energy providers to avoid delays or limitation in deployment caused by insufficient grid capacity. Areas such as rural countryside, where the grid
was not designed for heavy usage, will need extra attention to ensure faults do not appear.
With the correct funding, these infrastructure issues are solvable and are not limitations to introducing EVs to the UK on a widespread basis. Other countries have done it. China originally just subsidised electric buses but changed their policy to address charging infrastructure as well when inefficiencies grew. When China changed its policy, development scaled up more effectively.
India experienced the same woes, with its FAME scheme not addressing infrastructure adequately for demand. The government elected to join-up FAME and PM e-Bus Sewa Scheme to support both buses and infrastructure, in turn allowing hundreds of cities to change over to electric buses.
Regional characteristics can impact
EV adoption, as Brazil, Indonesia, and Mexico are discovering due to their terrain and climate conditions, and the UK is now learning due to its socio-political makeup. London and the Southeast have better existing infrastructure than the rest of the UK, meaning there is catch-up to be played to bring the country to a level playing field.
URBAN VERSUS RURAL
Urban areas have been given a preference over rural areas when rolling out EV buses, partly due to their pre-existing infrastructure investment advantage. Cities and towns may already contain dedicated charging hubs and have grid capacity upgrades. Cities, by their very nature, are dense and compact with many opportunities for stopping to recharge due to shorter routes and numerous
Cities and towns have a political incentive to incorporate electric buses, with more zero-emission zones, similar to the ULEZ, to tackle the rise of air pollution in big cities
depot facility options. The countryside is the complete opposite to this, where routes are long and depot options are limited due to the much weaker national grid connections in the area. This makes placing depots more difficult, requiring grid improvements on the entire area.
Having longer routes in the countryside also demands more of the battery. Whereas the shorter routes of the city can be completed without using a significant chunk of the battery life, longer country routes risk using much more of the battery life and potentially running out on the road – although this is unlikely.
Cities and towns have a political incentive to incorporate electric buses, with more zero-emission zones, similar to the ULEZ, to tackle the rise of air pollution in big cities. Funding is allocated in bigger chunks towards
urban areas compared to rural areas, which do not have the same air quality concerns to tackle.
Funding from the Zero Emissions Bus Regional Areas (ZEBRA) programme provides rural areas with the means to not be left behind by metropolitan developments, with £37.8 million to allocate across 319 new zero-emission buses in England before spring 2027. Private investment props up the investment which aims and making cleaner and greener buses.
Hull City Council received £3.9 million to aid 42 new electric buses along with a charging infrastructure rollout. Similarly, West of England Combined Authority is set to receive nearly £20 million for 160 e-buses coupled with tackling local grid capacity issues and provide charging points throughout the region.
ARRIVAL OF THE FUTURE
Both political, economic, and environmental issues are pushing us increasingly towards EV adoption, with the increasing rarity of crude oil and the fears about its ecological impact. Large funding is required for infrastructure to make EV buses a reality, as currently, the country is not ready for a full EV bus rollout.
Despite the costs, the benefits still make the project worthwhile. Switching to EVs and improving grid infrastructure is futureproofing the country for future developments, rather than constantly playing catch-up to the latest world developments. Having a stronger grid system not only benefits EVs but any other electric developments that come in the future, including development projects.
Fike Blue is designed to stop cascading thermal runaway
LAYERED APPROACH TO LITHIUM-ION
Mark Kendall discusses the various methods of protecting energy storage systems from the effects of thermal runaway
In the evolving world of energy storage and electrification, the dangers associated with lithiumion batteries - particularly thermal runaway - are often misunderstood and miscommunicated. At the Vehicle Electrification Expo in Birmingham, Mark Kendall, director - fire solutions group UK & Europe at Fike Corporation, delivered a talk on the layered approach needed to mitigate risks in lithium-ion battery systems, emphasising thermal management, explosion control, early warning detection, and preventive maintenance.
THE TRIGGERS
“Ultimately, it’s the breakdown of a
separator layer within a battery cell that causes a massive chemicalelectrical reaction,” Kendall explained. This breakdown allows for an internal short circuit, which sparks an exothermic reaction; a rapid release of heat and gas that initiates what’s known as thermal runaway.
Once this reaction begins, intervention becomes nearly impossible. “Once that first cell has gone into thermal runaway… there isn’t anything that you can do to stop it,” Kendall continued. “The separator layer’s broken down. The chemical reaction has already started.” This harsh reality dispels a common myth in the fire protection industry - that
thermal runaway can be halted midevent using aerosol systems, which Kendall said is not true.
CASCADING THERMAL RUNAWAY
The real danger lies in the domino effect, Kendall explained: “What we now get is a cascading event of that heat from the first cell affecting the next cell,” leading to a full-scale chain reaction. The progression continues through the battery module and potentially into adjacent modules. This leads to off-gassing, the release of hydrogen-rich gases as the battery’s electrolyte boils and ruptures. “A single cell produces
enough hydrogen to put a shipping container above its lower explosion limit,” Kendall said. The flammable vapour cloud ignites when exposed to a heat source, resulting in what many mistakenly call a “lithium-ion fire.” He clarified: “The term ‘lithium-ion fire’ is used to cover every part of this event, but it’s actually just a byproduct.”
Kendall highlighted the confusion caused by the misuse of terminology. “These terms - thermal runaway, cascading thermal runaway, offgassing, lithium-ion fire - they aren’t interchangeable,” he stressed. Misclassifying the stages of a battery incident can lead to ineffective safety strategies.
ANALYSIS FORMS THE FOUNDATION
A critical part of risk mitigation is understanding the behaviour of each specific battery configuration. “Every cell is different… you can have two modules with the same chemistry, but the way the event goes through can be very different,” Kendall said. For
Misclassifying the stages of a battery incident can lead to ineffective safety strategies
this reason, battery hazard analysis is essential. This involves performing a free burn test, intentionally heating the cell to its thermal runaway threshold (typically between 180°C and 230°C) to gather data on gas emissions, failure timing, and heat propagation.
Kendall outlined a five-layer protection model, emphasising that no single solution can mitigate all potential outcomes.
LAYER ONE: THERMAL MANAGEMENT
Thermal management is the first and most critical line of defence. “The earlier the intervention, the better the chance you have of stopping an event,” Kendall said. Strategies include physical thermal barriers, spacing modules to reduce heat transfer, and the use of active systems like their proprietary direct ejection fluid. “When we pick up that there’s a thermal runaway event… we release the fluid into the module,” he continued. “It pulls the heat from the cells, stopping that heat from transmitting to the next cell.” The result is a more controlled situation requiring significantly less fluid than conventional methodsabout 120 litres compared to millions of litres of water.
LAYER TWO: EXPLOSION CONTROL
Even after suppressing a fire, hydrogen gas may linger and pose an explosion risk, Kendall said: “It’s very easy to end up in an explosive atmosphere from lithium-ion batteries.” Explosion control can involve deflagration vents, which direct explosions safely upward, or exhaust ventilation to keep gas concentrations below critical limits. However, active purging systems can be expensive due to the need for explosion-proof certification.
LAYER THREE: EARLY WARNING DETECTION
According to Kendall, detection systems are crucial: “The earlier you can pick up an event, the greater the chance of success.” Technologies
include digital temperature sensing cables, smoke detection, and most importantly, hydrogen and VOC gas sensors. These sensors often detect changes before a cell physically ruptures. Battery management systems (BMS), while useful, are “not designed for safety systems,” and are therefore secondary in this application.
LAYER FOUR: PREVENTION
Prevention focuses on identifying external factors that might trigger battery failure, such as humidity, corrosion, or electrical faults. “80% of these events are started by something else, not the battery itself,” Kendall added. Traditional fire suppression systems like FK-5-1-12, fluorinated ketones, and aerosols are particularly effective at protecting auxiliary components such as inverters and switchgear.
LAYER FIVE: SUBSYSTEM PROTECTION
The final layer targets supporting equipment. “It’s about protecting things that can cause the batteries to go into thermal runaway, not about protecting the battery itself,” Kendall said. Smallscale fire suppression systems ensure that secondary failures don’t become catastrophic events.
UNDERSTAND, DESIGN, TEST
Kendall concluded with a clear message: “Make sure you understand the risk. Especially if someone’s trying to sell you a system.” He emphasised testing any mitigation strategy with the actual battery system it’s intended to protect, adding, “Just because something works on one battery and that chemistry looks a little bit similar doesn’t mean it’ll work on another.”
As lithium-ion technology becomes more integral to energy and transportation systems, understanding and mitigating thermal runaway is not just a technical challenge, but a safety imperative.
DRIVING BATTERY QUALITY
How industrial CT and automation are transforming electric vehicle battery design and manufacturing
As the electric vehicle (EV) market matures, the demand for precision, speed, and consistency in battery manufacturing is increasing. Quality control challenges in battery cells, modules, and packs are pushing OEMs and suppliers to rethink their inspection strategies, especially as production scales into the hundreds of thousands and beyond.
Hexagon, a global leader in metrology and manufacturing intelligence, is at the forefront of this evolution. Leveraging industrial computed tomography (CT), software automation, and advanced analytics, Hexagon is enabling automotive manufacturers to inspect and validate critical internal battery components in a fraction of the time once required. At the heart of this transformation is VGStudio Max, Hexagon’s CT data analysis software, now integrated into cloud platforms and scalable inspection workflows.
“Automotive battery manufacturing is incredibly complex. Something as simple as the ‘exit angle’ of a cathode
Hexagon presented its latest advances and technologies at Hexagon Live 2025 in Las Vegas
Users can streamline their analysis with precise evaluation and visualisation features
The Battery Anode Overhang Analysis offers a range of functions to detect segmentation failures
can make or break the performance and safety of the battery,” explains Roger Wende, senior business development manager at Hexagon. “In some cases, we’ve seen engineers spending up to an hour manually inspecting a single battery using basic tools. It’s just not sustainable when you’re trying to ramp up to production volumes.”
INTERNAL DEFECT DETECTION
Unlike traditional non-destructive testing, CT scanning allows engineers to peer into the internal structure of batteries, layer by layer, without disassembly. From detecting voids and cracks to verifying correct stacking of anode and cathode sheets, CT provides volumetric data that is essential for quality assurance.
“We’re looking at things like curvature, exit angles, and overhangs,” Wende says. “If that exit angle is too steep, it could cause short circuits or failures under stress. CT lets us quantify these variables with precision, and then our software automates the analysis.”
The data captured by CT is rich and detailed, which also means it is massive in size. This is where VGStudio Max comes in. Originally developed to visualise large datasets, the software now includes advanced modules for nominal/ actual comparisons, wall thickness measurement, and porosity analysis.
AUTOMATING ANALYSIS
Not only is manual inspection slow, but it can also be inconsistent. Battery manufacturers are increasingly turning to automated CT data analysis to drive throughput and repeatability.
“Once you’ve got the CT scan, you don’t want someone sitting there clicking through 500 layers by hand,” Wende notes. “Our tools can automatically identify and measure key features like cathode overhang or anode count and then flag any anomalies based on tolerances you’ve defined.”
VGStudio Max allows users to apply tolerances directly to critical features - such as maximum curvature or minimum electrode separation
– and automatically categorise parts as good or bad. The software can also generate detailed visual and statistical reports to support traceability and root cause analysis.
“What we’re most interested in is understanding why a battery fails inspection,” says Wende. “Show me the report, show me the image – let me see if it’s a real failure or not. That kind of root cause capability is a game changer.”
PROCESS OPTIMISATION
In addition to informing quality assurance, inspection data also feeds process improvement, Wende says. By tracking key performance indicators (KPIs) over time, manufacturers can detect early signs of drift, equipment wear, or material inconsistency.
“Let’s say you’re measuring the exit angle or the average thickness of the electrodes,” he explains. “You can put those KPIs on a dashboard, visualise the trends, and correlate them to upstream changes. Did something go wrong with the welding machine?
Hexagon Live 2025
Are we seeing more variation from a particular supplier? CT helps you answer those questions.”
And as manufacturers seek to improve first-time yield, software tools are evolving to support statistical process control (SPC) and machine learning. “Some of our newest developments include machine learning-based deep segmentation,” Wende adds. “That means faster defect detection and more intelligent sorting –even with noisy or complex data.”
SCALING UP
Hexagon’s software suite is increasingly cloud-enabled, designed to operate across global manufacturing networks. In particular, the integration of VGStudio Max data into enterprise systems like Q-DAS (Hexagon’s quality data management platform) is enabling batch-level and longitudinal analytics.
“Every car door manufactured in Germany probably has Q-DAS behind it,” Wende says. “Now, we’re bringing CT inspection data – originally a standalone desktop process – into the same ecosystem.”
This integration is crucial for scaling up. “We’re not just sampling one in 100 anymore,” he explains. “The goal is to scan every single battery. That’s the holy grail. But to do that, you need fast CT hardware, smart automation, and enterprise-
level software to handle the data.”
Hexagon is also pushing CT into real-time workflows. With recent developments, VGStudio Max can now operate in dynamic mode, accepting laser scanner data in realtime and feeding it into live analysis routines, including surface roughness checks and weld inspection.
APPLICATIONS BEYOND AUTOMOTIVE
While automotive remains a primary driver, other industries are taking notice.
“We’ve had aerospace teams borrowing tools from automotive,” Wende says. “They’re looking at CT for similar reasons – safety, performance, and traceability – but with even tighter tolerances and lifespans.”
Even in heavy-duty applications like rail or aerospace propulsion, the same concerns apply. “You’re dealing with high current and energy density,” Wende continues. “Whether it’s a passenger EV or an aircraft battery, defects in welds or materials can be catastrophic.”
One particularly challenging component is the hairpin. These tiny copper elements, which are key to EV motor performance, must be manufactured with extreme consistency to avoid torque ripple and electrical faults.
“Every motor can have over 200 hairpins. If any of them are even slightly off, it affects performance,”
Everyone talks about EVs, but actually building them – at quality, at scale – is incredibly hard
Wende explains. “We do a lot of optical scanning there, but CT helps us verify internal welds and voids.”
DESIGNING FOR MANUFACTURABILITY
According to Wende, the biggest gains for OEMs come not from post-production inspection, but from designing out defects before they can occur.
“No one wants a battery to go into a car with a problem,” Wende says. “The earlier you detect and solve those issues, ideally in design or preproduction, the lower your costs and the higher your yields.”
This philosophy underpins Hexagon’s broader strategy: integrating inspection, design simulation (via tools like Digimat and Nastran), and manufacturing planning into a unified digital thread.
“Because we’re part of Hexagon, we’ve now got teams working across all domains—metrology, FEA, additive manufacturing, and so on,” Wende says. “It’s all about building smarter workflows that scale.”
As the EV industry continues to transition to high-volume production, the need for scalable, automated, and intelligent quality control systems will be critical. Industrial CT, coupled with powerful analysis software like VGStudio Max, is helping manufacturers to detect and prevent defects, optimise processes, and ultimately deliver safer and more reliable vehicles.
“We’re still immature as an industry,” Wende concludes. “Everyone talks about EVs, but actually building them – at quality, at scale – is incredibly hard. The good news is, with the right tools, it’s becoming achievable.”
Ensuring an optimal anode overhang is key for the performance and lifespan of lithium batteries
Extreme bending of the anode sheets can cause delamination or cracks in the active material
ZF’s new toolkit is built to meet the latest cybersecurity and regulatory standards
TRAIL MIX
Dr Peter Bruns tells Louise Davis how a new modular toolkit will make life easier for commercial vehicle trailer manufacturers
The introduction of a suite of services designed to simplify software updates for trailer manufacturers does rather raise the question of ‘why is there so much complexity in this field that such a solution is necessary?’
“The digital transformation has seen vehicles – including commercial vehicle (CV) trailers – become more intelligent and connected, increasing the number of software updates necessary over the lifetime of the vehicle,” answers Dr Peter Bruns, a trailer launch application engineer with ZF. “This in turn has driven
the increase in global regulations to ensure software updates in vehicles are secure and traceable.”
The UN/ECE R156 regulation is a prime example here: its purpose is to create a framework for secure vehicle software updates. Bruns says that regulations such as this have evolved in line with software development and are there to ensure that centralised, secure update mechanisms are in place to reduce vulnerability to cyber threats. “As software in this space is increasingly diverse, with trailers often integrating components from multiple suppliers, each with its
own software and update protocols, managing the traceability of these can be challenging,” he explains.
“In addition, manual or fragmented update processes in the field can lead to extended vehicle downtime, impacting fleet efficiency.”
SUITE SHOP
ZF’s means of cutting through these layers of complexity is the Software Update Management System (SUMS) service suite, a modular solution for trailer software updates that comes with ISO 24089 certification, making it the first Tier 1 supplier serving the
Dr Peter Bruns with ZF’s ISO 24089 certificate
CV trailer industry to achieve this.
Bruns notes that modular design enables OEMs to ‘pick and mix’ the elements of the suite that best align with their needs: “This approach lowers the barrier to entry and allows gradual adoption, making it attractive even for smaller manufacturers,” he details. “For example, as an initial investment a manufacturer can choose the consulting services component to assess and ensure its readiness to comply with the regulations, then opt to integrate the SUMS software-as-aservice (SaaS) tool later on.”
But why should a trailer manufacturer invest in a toolkit to manage its software updates? “Developing an inhouse software update management solution requires a team of specialised experts and can be resource-intensive and time consuming – this may not be the most efficient solution for every manufacturer,” explains Bruns. “For those who do not have these resources, we now offer a ‘ready-to-go’ 360° toolkit – built to meet the latest cybersecurity and regulatory standards.” He adds that the ISO 24089 certification for trailer software updates provides customers with a strong proof-point that the new SUMS service suite “will enable them to achieve and maintain regulatory compliance”.
Bruns highlights the suite’s holistic vehicle approach as a key differentiator. He says: “It’s usable for ZF products and/or third-party technologies (other solutions focus on isolated systems or supplier brands only), providing secured access to the OEM and its relevant eco-system – such as suppliers, workshops and auditors. This releases trailer OEMs from significant efforts required to digest, manage and implement the complex regulatory requirements to achieve the relevant certification. Additionally, the scalable design reflects evolving industry standards and regulations, ensuring long-term relevance.”
FEEDBACK LOOP
As ZF’s SUMS expert, Bruns reports positive feedback from the prospective customers he has been speaking with since the May 2025 launch. “Customers appreciate the holistic vehicle approach as well as the flexibility and modularity of the suite,” he confirms.
Bruns also reveals that customer feedback is what inspired the development of the new offering.
“As a trusted technology partner of many trailer manufacturers, we listen closely to our customers, and outcomes from our joint discussions are what prompted us to address the SUMS topic holistically,” he recalls. “According to their needs, we developed a 360°
solution with the whole trailer in focus – rather than an isolated element such as the electronic braking system. By embedding safety and security into every step of the update process, the toolkit helps trailer manufacturers maintain reliable, regulation-ready software update procedures in today’s increasingly software-driven environment.”
MODULAR APPROACH
ZF’s SUMS suite consists of five modular elements to support trailer OEMs in managing and documenting the full lifecycle of software updates in compliance with the stringent requirements of the UN/ECE R156 regulation. These include the ISO 24089-certified SCALAR SUMS SaaS platform, which manages, records and verifies software and hardware versions for any UN/ECE R156 relevant devices. Consulting services to help trailer OEMs navigate UN/ECE R156 complexities are also included in the suite, as well as a comprehensive handbook, templates and checklists that help to clarify certification requirements. To further support trailer manufacturers, the suite also includes training programmes for OEMs and suppliers, while user training is provided through the SaaS platform. A portfolio of SUMS-ready trailer technologies – such as the TEBS-E7 and iEBS electronic braking systems, OptiTire tyre pressure monitoring system (TPMS) and the SmartBoard control panel – completes the offering.
The SUMS suite features five modular elements
BUILDING TRUST
How can companies learn to trust AI within battery research & development?
Left screen: Battery test planning and design optimisation in Monolith. Right screen: Interactive heatmap of anomaly detection used for cell validation experiments. Image via Monolith Battery Report 2024
As artificial intelligence (AI) and machine learning (ML) continue to make inroads into engineering research and development (R&D), concerns around trust and transparency remain front and centre. The field of battery development for electric vehicles (EVs) is no different, despite the fast pace of technology development and adoption within the e-mobility sector. However, AI software firm Monolith AI is aiming to bridge this trust gap.
“We are on the commercial side of applying AI and ML research into the R&D value chain,” said Marius Koestler, Monolith AI’s vice president of AI for batteries, at the recent Vehicle Electrification Expo. “Now, as you can imagine, we quite often get the question: Can you trust AI for engineering?”
THE BLACK BOX DILEMMA
Koestler began his presentation with an example of generative AI which showed a rather unrealistic video of a
Monolith focuses on non-generative AI and ML applications that serve specific engineering use cases
digital human being jumping on a mat that, to say the least, denied the laws of physics. “If this is the best that $18 billion of investment can produce in terms of realism and approximation of first principles for somebody jumping on a mat, why should you and I ever trust AI for complex engineering R&D problems?” he asked.
The point of Koestler’s example was not to mock the technology, but to illustrate the limitations of purely data-driven models, especially those that appear to understand physics but ultimately do not. In contrast, Monolith focuses on non-generative AI and ML applications that serve specific engineering use cases. “This is within material and design selection, data analysis, finding new insights for automating data review, and running simulations and predictions of intractable physics within a confined design space,” Koestler explained.
Still, though, the issue of trust persists, he acknowledged: “We, as humans, intuitively don’t like it because it feels like a black box.
Consumer demand for automobiles boasting longer ranges and faster charging is a significant driver of EV battery advancements
We don’t understand how it reaches its conclusions, and we really can’t understand how it makes its decisions.”
EXPLAINABLE AI
Koestler argued that AI doesn’t have to be a black box, and that there are methods which are often overlooked that can make it explainable and therefore more trustworthy. One such method is LIME, or Local Interpretable Model-Agnostic Explanations. To demonstrate, he referenced a wellknown ‘cat and dog’ problem in AI image recognition.
“If you now present it with a picture that clearly has both a cat and a dog, the model will still say it’s just a catbecause it’s never seen both together,” Koestler said. However, by blanking out different sections of the image and repeatedly asking the model what it sees, the AI can begin to distinguish between the parts that signify ‘cat’ and those that signify ‘dog’.”
“This same simple, useless model can now also tell you that there’s likely both a cat and a dog in the same picture, even though the model has never seen a picture of both together,” he added. “And this approach is called LIME.”
This method, while simple, is already widely used in fields such as radiology, where doctors need to know not just that a tumour exists but where it is and whether there are multiple tumours in one image. “It allows you to use fairly simple AI and ML models and make them explainable,” said Koestler.
APPLICATIONS IN BATTERY R&D
The same principles apply to battery diagnostics, where X-ray imaging
is increasingly used to inspect cells without destroying them.
“X-rays are used to evaluate batteries to avoid teardown,” Koestler said. “Because the teardown of the battery after a catastrophic failure would destroy the evidence.”
But Koestler pointed out that the majority of battery-related data is in time-series form, not images. In such cases, Monolith’s platform enables engineers to create heatmaps of anomalies in timeseries data. “You can drill down, and it shows you which channel and what timestamp contributed to the model believing there’s an anomaly right there,” he explained.
By using image analysis tools powered by AI, engineers can evaluate battery performance, identify causes of failure, and iterate on future designs more rapidly. “It’s directly applicable to battery research,” he added, especially when integrated with explainable AI methods like LIME which allow engineers to visualise the basis for AI decisions.
This approach is particularly valuable in labs dealing with longterm aging studies or complex failure analysis. When used correctly, Koestler said, “AI can indeed be very explainable, and perhaps it can be even more trustworthy than, let’s say, a 30-year expert within the field reviewing the data.”
TRUST IS ESSENTIAL
While technical approaches like LIME help, Koestler emphasised that building trust in AI is not only about algorithm design but also about human interaction. He likened
TEST, SAFETY, SYSTEMS
the process to onboarding a new junior engineer. At first, every step is reviewed. Then trust builds and eventually the engineer requires less oversight, not because the work is always flawless, but because the benefits of autonomy outweigh the risks of occasional error.
“It’s the exact same thing with AI,” he said. “In the beginning, you supervise closely. You give corrections. Over time, the cost of reviewing every output becomes higher than the benefit.”
Koestler also shared an internal case study from Monolith’s own journey. When the company first started applying AI to battery R&D, its customers were heavily involved in labelling data and validating results. “We weren’t battery experts then,” he said. “So we had to involve the subject matter experts in every part of model development.”
As Monolith’s internal battery expertise grew, the company began handling more of the work independently. But something unexpected happened. “The customers stopped trusting the models because they were no longer part of the process,” Koestler explained. As a result, Monolith deliberately reintroduced more customer involvement into model development in order to maintain trust.
HUMAN-AI COLLABORATION
Koestler’s final point was that trust in AI will be determined less by technical performance and more by the quality of the interface between humans and models. “It’s not always about the performance metrics, the recall or the precision,” he said. “It’s just as much about how we interact with the AI models.”
In battery R&D, where the complexity of battery systems, safety standards, and test environments are continually changing, human-inthe-loop design is crucial. “The most important determining factor on how fast one will adopt AI and ML in R&D,” Koestler concluded, “is to what degree we, as vendors like Monolith, are able to make very good user interfaces and interactions between customers and the models - so that they can gradually, but as fast as possible, build trust.”
SENSING CHANGE
Diving into the latest sensor technology innovations within the rail sector
Railways are undergoing a transformative period driven by advances in sensor technologies that promise to improve safety, reduce downtime, cut emissions, and prepare the sector for full automation. This article rounds up some of the key recent developments across the rail industry, from wireless-powered sensors and realtime track temperature monitoring, to autonomous vehicle perception systems and a Europe-wide strategy for innovation.
SMARTER CONDITION MONITORING
RX Watt, a University of Glasgow spinout, has introduced a new class of battery-free sensors designed for realtime monitoring of rolling stock. These sensors harvest energy from radio frequency (RF) signals and wirelessly transmit key operational data such as temperature, vibration, and strain via Bluetooth. This eliminates the need for wired installations or battery
replacements, reducing environmental impact and maintenance costs.
Tested successfully at the BCIMO Very Light Rail Innovation Centre, the RF-powered sensors were shown to operate effectively on real rail vehicles, including trams and passenger carriages. Their ability to retrofit into existing systems without major infrastructure changes opens significant opportunities for rolling stock operators focused on preventive maintenance and sustainability.
Dr. Mahmoud Wagih, founder of RX Watt and a lecturer at the James Watt School of Engineering, said: “Monitoring air quality, occupancy, and wear and tear are crucial to sustainable and resilient transport. With radio-frequency power delivery, we eliminate the dependence on batteries or energy harvesting from the environment, enabling continuous, maintenance-free monitoring.”
This advancement aligns with the UK’s broader innovation goals, having received backing from Innovate UK
under the Contracts for Innovation programme, and reflects growing recognition of the role that lowmaintenance, low-power sensing will play in modern rail systems.
TACKLING TRACK FAILURES
Hot weather continues to pose a major threat to railway safety. Steel rails expand in heat, and if unmanaged, can buckle, posing derailment risks and causing extensive service delays. In 2024 alone, rail buckling was responsible for 240 days of cumulative delays in the UK. Historically, manual magnetic thermometers have been used to monitor track temperatures—an approach that is both labour-intensive and disruptive. However, since 2023, Network Rail has partnered with suppliers to deploy remote rail temperature sensors capable of taking readings every 15 minutes and transmitting data via mobile networks. These smart sensors send automated
Dr Mahmoud Wagih (left) and Mr James Stephenson (right) at the BCIMO rail innovation centre
Network Rail can now monitor much larger areas of track in real time
Field of views of the sensor setup in AutomatedTrain
alerts when specific temperature thresholds are reached, enabling timely intervention without manual trackside monitoring. This development not only increases safety but also improves operational efficiency by allowing targeted speed restrictions instead of blanket slow-downs.
The system is already in use across several regions, with ambitions for network-wide implementation, particularly as climate change continues to exacerbate extreme temperature events.
FULLY AUTOMATED
Another critical frontier is the move toward fully automated, driverless train operations. In Germany, the AutomatedTrain project - led by Digitale Schiene Deutschland (Digital Rail Germany) - is piloting technologies to enable automated train preparation, staging, and storage.
The project, in collaboration with Siemens Mobility and Bosch Engineering, integrates an advanced multi-modal environmental sensor suite into Siemens Mireo and Alstom Class 430 S-Bahn trains. This setup includes:
6 Lidar units for mid- and longrange detection
7 HDR colour cameras for object recognition
3 radar sensors for mid-range obstacle detection
8 ultrasonic sensors for closerange awareness
2 long-wave infrared (LWIR) cameras to detect heat sources
These sensors are designed to deliver human-equivalent situational awareness, functioning reliably in varied environmental conditions such as fog, snow, and darkness.
The fusion of sensor inputs is used to develop AI-based perception algorithms, which will be validated at the Siemens Mobility Test and Validation Centre and in field tests on the Stuttgart S-Bahn.
The system is supported by a robust data infrastructure including a Vehicle Data Logger and a centralised data factory that processes and uses the data for continuous machine learning model improvement. This scalable approach is essential for achieving safe, interoperable automated rail operations across diverse train types and use cases.
COORDINATED STRATEGY
All these innovations are aligned with the vision laid out by the Europe’s Rail Joint Undertaking (EU-RAIL) in
its recent high-level paper advocating for a bold public-private investment strategy in rail innovation. The plan proposes €18 billion in co-investment from 2028 to 2034, with €3 billion dedicated to research and innovation and €15 billion for pre-deployment activities.
Among the priorities are: Agility: Through modular digital systems and streamlined certification
Resilience: With emphasis on cybersecurity and climate adaptation
Competitiveness: By lowering lifecycle costs and increasing industrial leadership
Giorgio Travaini, executive director of Europe’s Rail JU, said: “By simplifying the rail system and reducing complexity, we can increase economies of scale and make the sector more competitive. This creates lasting value for both large and small players across the European rail ecosystem.”
The strategy underlines the importance of interoperable sensorenabled solutions as foundational to the Single European Rail Area (SERA), helping to triple high-speed passenger rail use and double freight transport by 2050.
Visualisation of the field of view of all individual sensors in AutomatedTrain according to their installation position and orientation in the train front
High-performing delivery vans require intensive vehicle and component testing
DOOR TO DOOR
ASC Sensors shares how inertial sensors are improving the performance of delivery van doors
Vehicle components such as driver, rear and sliding doors of delivery vans are exposed to extreme stress. A global manufacturer of popular vans, therefore, attaches great importance to ensuring long-term operational stability of its products. Accelerometers and gyroscopes made by ASC help to adequately design delivery vehicle components based on solid measurement data and to dampen vibrations through suitable measures and materials. This enables the automotive producer to live up to its claim of offering vehicles of
outstanding quality and longevity.
OPTIMISING HEAVILY STRESSED VEHICLE COMPONENTS
Imagine you are delivering parcels. Every few minutes, you pull open the door of your van and slam it shut again, with varying degrees of force or patience on level, ascending or descending roads. Guiding the side door manually, too, generates different forces from jerking it open, accelerating and stopping it abruptly. All this hundreds of times a day, six days a week, 45 weeks or more a year.
Uneven road surfaces play a role, too. When you drive through a pothole, the vehicle jerks upwards at extreme speed. Parts twist, rub and bump against each other. It is no surprise, therefore, that original manufacturers
The analog ASC 4415LN-025 accelerometer
The ASC 271-300 gyroscope
put vehicles and component parts through their paces in elaborate test procedures. At this particular producer, inertial sensor systems from ASC are used in week-long endurance test set-ups in order to help with suitable dimensioning, material selection and damping on the basis of highly precise measurement data and to increase the operational stability of important vehicle components.
PRECISION SENSORS IN CONTINUOUS USE
Testing a new vehicle door can take six weeks or more – in perpetual mode. Analog ASC 4415LN-025 accelerometers and ASC 271-300 gyroscopes are used to realistically depict various stress scenarios, intensively test the durability of different door designs and the effectiveness of diverse interventions to reduce stress and increase longevity.
ASC’s capacitive sensors are installed at selected measuring points. While the doors are opened and closed in a wide variety of ways, the sensors record exact accelerations,
rotational movements, maximum speeds and reversal points. All other relevant forces are calculated from this. On the test bench, components are then subjected to the same forces and stress over an extended period.
Uniaxial accelerometers from the ASC 4415LN range are particularly suitable for these intensive test series. Their flat design simplifies quick installation – a fundamental advantage in test bench applications. With a measuring range of 2-400g, they are based on proven MEMS technology and the capacitive measuring principle. ASC’s low-noise (LN) accelerometers provide an outstanding signal-tonoise ratio, essential for demanding measurements of smallest frequencies and amplitudes.
The uniaxial gyroscopes of the ASC 271 series consist of MEMS vibrating ring sensor elements whose micromechanical silicon structure makes them extremely insensitive to external shocks and vibrations. Therefore, they are ideal for use in harsh environments. They meet industrial grade requirements in terms of maximum
achievable precision and offer an outstanding choice for dynamic roll, pitch and yaw angle measurements in automotive applications and beyond.
ROBUST, RELIABLE, COLLABORATIVE
Today, innovative sensor technology is not only used on van doors, but on many vehicle components. At least, wherever vibrations or rotational movements emerge or bear an effect.
The collaboration between ASC and the van manufacturer is running well. “We place great importance on really listening to the needs of our customers and on developing solutions that exactly meet those needs,” says Renate Bay, managing director of ASC Sensors.
“After all, every sensor installation means a lot of work for the customer, so we focus closely on ensuring its benefits and outcomes.”
Words by Oliver Stohlmann on behalf of ASC Sensors. www.asc-sensors.de
The evolution in sensor technology
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.
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The IMI EV TechSafe report: EV TechSafe Technician Forecasts
RESHAPING THE TRANSPORT SECTOR
Rounding up the latest training and upskilling initiatives across the transport industry
As the transport sector accelerates towards a future driven by decarbonisation, digitalisation and resilience, workforce development has become a critical enabler. A wave of new initiatives across hydrogen, electric vehicle (EV) infrastructure, rail technology, digital twins, and cybersecurity training are creating additional opportunities for engineers and technicians to upskill and future-proof their careers. Here, International Transport Manufacturer summarises some of the latest announcements.
TALENT IN HYDROGEN
Hydrogen UK has opened nominations for the 2026 Hydrogen UK Awards, an initiative designed to spotlight
innovation, thought leadership, and workforce development in the hydrogen economy. As part of the Hydrogen UK Annual Conference and Awards (Birmingham NCC, 10–11 March 2026), the programme includes a dedicated “Future Hydrogen Leader” category, aimed at recognising emerging professionals and young engineers making an impact in hydrogen deployment.
Other categories – such as Hydrogen for Transport, Innovation Project, and Industrial Application – serve to highlight the growing skills demand in applying hydrogen technology across multiple sectors. Free and open to individuals, companies and institutions, the awards provide a national platform to celebrate and promote excellence in hydrogen-related disciplines.
INFRASTRUCTURE INVESTMENT
The UK government’s £63 million investment in EV infrastructure, announced earlier this year, was welcomed by industry. However, the Institute of the Motor Industry (IMI) has warned that the real-world impact of this funding may be limited unless urgent action is taken to address the growing EV technician shortfall.
“Only around 26% of UK vehicle technicians currently hold an EV qualification,” said Sarah Sillars OBE, Interim CEO at the IMI. “As the EV parc grows, the postcode lottery of access to qualified servicing professionals is going to worsen.”
The IMI projects that the technician shortfall could exceed 29,000 by 2035, threatening to undermine adoption and consumer confidence. To counter
this, the IMI is calling for targeted government support in training delivery and apprenticeships, and has published a workforce strategy manifesto, Driving the Future of Automotive Professionals. It includes plans to enhance recruitment pipelines, offer modular upskilling, and establish career progression frameworks to retain skilled workers.
RAIL INNOVATION
In June 2025, construction began on the Derbyshire Rail Industry Innovation Vehicle (DRIIVe), a major new rail training and R&D centre being developed next to the historic Barrow Hill Roundhouse near Chesterfield.
Scheduled to open in 2026, DRIIVe will feature:
Classroom and training areas for level 2 through postgraduate education
A commercial workshop for industry R&D
A digital laboratory for advanced simulation and prototyping
On-site presence for rail supply chain businesses
Funded through the Staveley Town Deal, with contributions from local and regional authorities, DRIIVe aims to deliver a full pipeline of rail engineering talent.
“This exciting project will not only create jobs and skills opportunities but also inspire the next generation of rail professionals,” said Claire Ward, Mayor of the East Midlands. Mervyn Allcock, Barrow Hill Roundhouse Manager, added: “We’re already seeing interest from the sector—this facility will set us apart as a hub of innovation.”
CYBERSECURITY TRAINING
With transport systems becoming increasingly digitised and interconnected, the CYRUS project has launched a new suite of free cybersecurity training courses tailored for the transport and manufacturing industries. Available online until October 2025, these short courses are designed for both technical and non-technical personnel, ranging from engineers and operators to HR and finance professionals.
Developed by Deep Blue and a consortium of EU partners
including UIC, the training modules are structured across three levels (beginner, skilled, expert) and take under four hours each to complete. Learners can expect:
Real-world case studies
Interactive e-learning content
Certificates of Completion or Excellence
Optional live webinars with cybersecurity professionals
“Cybersecurity is no longer just a technical issue - it’s a businesscritical skillset across all levels of an organisation,” said Alessia Golfetti, CYRUS Project Coordinator. “With AI and automation increasing attack surfaces, building human resilience is as important as investing in secure systems.”
DIGITAL TWINS
The newly launched UK Digital Twin Centre in Belfast represents a major step forward in immersive, systemslevel training and research. Operated by Digital Catapult and funded by the Belfast Region City Deal and Innovate UK, the facility is equipped with a 360-degree immersive space, cyber-physical laboratories, and testing environments for simulated
industrial scenarios.
The centre supports engineering teams from aerospace, maritime, and defence sectors, helping them develop and deploy digital twins of assets, processes, and infrastructure.
A six-month Accelerator Programme - now open for expressions of interest - offers Innovate UK-funded collaboration opportunities between tech SMEs and industry partners. Participants receive mentorship, workshops, and tools to develop proofs of concept using enabling technologies like IoT, data integration, and virtual simulation.
“Digital twins are unlocking real business value, from optimising design to enhancing supply chain resilience,” said Susan Bowen, CEO of Digital Catapult. “The new centre offers a national resource to demystify and democratise access to these technologies.”
The combined effect of these initiatives is a growing ecosystem of opportunity. Each programme – from hydrogen recognition awards and rail engineering hubs to immersive digital twin training – serves a critical function in preparing the UK transport workforce for the next decade.
Hydrogen UK Awards ceremony 2025
INDUSTRIAL AM IN THE SPOTLIGHT
Formnext 2025, Europe’s largest exhibition for additive manufacturing (AM) and next-generation industrial production, will take place from November 18–21 in Frankfurt am Main. This year, the event is placing emphasis on the commercial potential and industrial integration of AM technologies, highlighting their growing impact in sectors such as mechanical engineering, aerospace, and digital manufacturing.
The exhibition, organised by Mesago Messe Frankfurt and supported by the VDMA’s Additive Manufacturing Working Group, is geared toward showcasing practical, scalable AM solutions that offer measurable benefits, particularly in terms of performance, efficiency, and profitability. As Christoph Stüker, Vice President Formnext, notes: “With the increasing industrialisation of additive manufacturing, commercially successful applications are growing in number and relevance. Sharing these use cases is essential to establish AM in other sectors and develop new solutions for specific challenges.”
INDUSTRIAL APPLICATIONS TAKE CENTRE STAGE
One of the standout features of Formnext 2025 is the continued expansion of the VDMA’s compendium of industrial AM case studies. These real-world applications, primarily from the mechanical and plant engineering sector, illustrate how companies are leveraging AM to optimise resource efficiency, reduce time-to-market, and produce functionally integrated components. The compendium aligns with this year’s theme for the VDMA Show Case Area: “Profitable Industrial Solutions,” emphasising that AM is not merely a prototyping tool, but a transformative manufacturing method ready for large-scale implementation.
MULTI-STAGE PROGRAMME
Formnext’s renowned three-stage format will once again structure the event’s conference programme into the Industry, Application, and Technology Stages – each tailored to specific facets of the AM ecosystem.
The Application Stage will present compelling case studies from a wide range of industries, including aerospace, medical and dental technology, architecture, and even jewellery and watchmaking. These examples illustrate how AM is being used to address application-specific challenges, whether in lightweight construction for satellites or the customisation of high-end consumer goods.
The Industry Stage will facilitate broader discussions around topics that affect AM adoption across all sectors. Key themes include sustainability, artificial intelligence, workforce development, investment trends, and the standardisation necessary to scale AM technologies. Notably, this stage will also explore AI’s emerging role in AM – from design optimisation to industrial metaverse applications.
The Technology Stage, dedicated to innovations along the AM process
will allow Formnext exhibitors to present their latest advancements in hardware, software, and materials. This includes developments in metal and polymer printing systems, postprocessing automation, and end-toend digital manufacturing platforms.
EXPANDING THE AM ECOSYSTEM
Formnext and the VDMA are committed to enhancing visibility for industrial AM and deepening the industry’s understanding of its economic potential. According to Dr. Markus Heering, Managing Director of the AM Association at VDMA, “To achieve the desired level of industry awareness, it is vital that expert networks such as the VDMA and highprofile platforms such as Formnext work together efficiently.”
As AM continues to transition from innovation to industrialisation, Formnext 2025 promises to be a critical touchpoint for decision-makers seeking to harness the full commercial value of the technology.
Formnext 2024. Image via Mesago/Mathias Kutt chain,
POWERING THE FUTURE OF MOBILITY
MOVE America 2025 will return as a definitive meeting point for leaders, disruptors, and visionaries shaping the future of transportation in Huntingdon Place, Detroit, 2425 September. Taking place in a dynamic, converged format, the event connects the entire mobility ecosystem, from automotive OEMs and fleet operators to charging providers, city governments, tech innovators, and investors.
With over 500 speakers across 18 specialised stages, MOVE America offers deep insights into core themes
such as Electric Vehicles, Smart Cities, Battery Technology, Autonomous Systems, ESG, and Connectivity. The event emphasises real-world impact, facilitating high-value conversations, strategic partnerships, and tangible business outcomes. Whether exploring cutting-edge business models or unveiling advancements in ADAS, MOVE bills itself as the place where transformative ideas meet industrial scale.
A standout feature is the Start-up Village, which showcases over 200 mobility start-ups poised to disrupt legacy systems. These emerging
companies gain access to toptier investors, media, and potential acquirers. The highly anticipated ‘Start Me Up’ Pitch Competition will see 15 start-ups selected to pitch live before a panel of investors. The winner will be crowned MOVE America Start-up of the Year 2025 and receive an exclusive feature on MOVEMNT, gaining visibility across the global mobility industry.
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.
Experience all around the show floor and on the stages how AM can make your production operations more efficient, flexible, and sustainable. Discover solutions that suit and improve your applications – and don’t miss the chance to engage with the experts and industry pioneers in Frankfurt. Get your ticket now! formnext.com/tickets
18 – 21.11.2025
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