ZLP Stade

Side by side with industry - research with full-scale plants im Full-Scale-Maßstab

Stade site

At the ZLP site in Stade, which also represents the Production Technologies department of the Institute of Lightweight Systems Engineering, science and industry are working together to develop new processes in order to better prepare innovations for industrial implementation.

The transition from idea to assessable application requires a professional research infrastructure on a full-scale, especially when it comes to implementation in production. This is particularly important for aeronautical applications with a technology readiness level (TRL) of 4 to 6, but also applies to other applications such as wind turbine rotor blades. The simulation of the processes is crucial for the efficient realisation of the research tasks and also offers the possibility of transferring the knowledge gained to different process and cycle rates.

The Stade ecosystem

The close cooperation between research and development institutions on the one hand and the Airbus plant in Stade on the other is often referred to as the "Stade ecosystem". The close cooperation between the DLR Institute of Lightweight Structures, the Fraunhofer Institute for Manufacturing Technology and Applied Materials Research, HP CFK, CTC GmbH, the industry association Composites United and the Airbus plant in Stade offers a unique environment for innovation and problem solving within the Airbus Group and now serves as a blueprint for many technology centres worldwide.

Map DLR Stade
Map DLR Stade.

Research topics at the ZLP Stade site

The research focus at the ZLP site concentrates on the development of customised manufacturing processes and efficient heating technologies as well as on digitalisation / Industry 4.0, virtual manufacturing and evaluation models. In close cooperation with other institutes of the German Aerospace Centre (DLR) and with national and international partners, the ZLP site in Stade conducts both basic and applied research.

Production made easy

Application-orientated manufacturing processes and efficient heating methods

Forward-looking transformation

Digitalisation / Industry 4.0, virtual manufacturing and evaluation models

Research infrastructure at the ZLP Stade site

On the equipment side, the ZLP Stade site covers production scenarios ranging from press, RTM and autoclave technology to fibre placement technology. All systems are digitally networked and equipped with state-of-the-art control and quality assurance technology. Production costs as well as resource and energy efficiency are analysed.

Efficient multi-robot fibre placement technologies

GroFi® research platform

The GroFi® large-scale facility is a research facility based on coordinated robots for the automated production of large components made of fibre composites. The aim of the research is to develop a production technology for the manufacture of large, high-integrity components using automated fibre placement processes.

Efficient infusion and curing processes

BALU® research autoclave

The DLR Institute of Composite Structures and Adaptive Systems operates the world's largest research autoclave at the DLR site in Stade. The BALU (Biggest Autoclave Laboratory Uni) autoclave is used to research new technologies in the field of fibre composite lightweight construction.

Automated manufacturing of near-net-shape volume components

EVo research platform

The EVo research platform at the DLR Centre for Lightweight Production Technology in Stade was designed for the fully automated and flexible production of fibre composite components using RTM (Resin Transfer Moulding) technology with an upstream preforming process.

Projects at the ZLP Stade site

ZEIT

The ZEIT project complements research into propulsion and fuelling concepts by focusing on suitable tank materials and industrial processing. Aviation research and ZeroE concepts strive for low-emission solutions with cryogenic fuels.

ZEUS

Thermoplastic, fibre-reinforced semi-finished products offer a wide range of advantages in aviation for structural components such as fuselages, including lightweight construction and new processing options. Their use requires reliable production processes and intensive research.

PredictEco

The overall project aims to provide a platform for evaluating and optimising the sustainability of resource-intensive manufacturing processes right from the design stage (→ measuring sustainability with digital technologies).

LeiWaCo

The use of hydrogen as an energy storage and energy carrier is seen as a key element for the success of the energy transition, as described in the national hydrogen strategy. One important aspect of this is the development of an infrastructure for the transport of hydrogen.

MÖWE

The aerospace industry needs to develop lightweight, high-performance structural components. Dry fibre placement technology precisely places dry fibre composites and offers promising solutions. Efficient processes are crucial for weight-optimised components.

OntOMaT

In the OntOMat project, a comprehensive ontology for various manufacturing processes and materials is being developed and linked with simulations. Testing processes and material cycles are also taken into account.

Current blog posts ZLP location Stade

Trade fair

JEC World 2024

Between 5 and 7 March 2024, the DLR Institute of Lightweight Structures and Design in Braunschweig and the DLR Institute of Structures and Design in Stuttgart represented DLR's expertise in lightweight construction at the leading European trade fair for fibre composites, JEC World in Paris.

KI-BASED CRACK DETECTION

Seeing through ice-cold

While the manual examination of microscope images of samples made of carbon fibre reinforced plastic (CFRP) is very time-consuming, the use of a suitable AI model represents a much more efficient alternative for analysing these images.

STORAGE OF CRYOGENIC HYDROGEN

HyStore project

In 2021, the DLR Institute of Lightweight Structures started the NBank project HyStor (Hydrogen Storage) as the first German project for the storage of liquid hydrogen (LH2) in composite tanks for use in aviation

News / Events from the ZLP Stade site

Pitch-perfect: the cardboard kings

DATIpilot

A bio-based moulding tool made of corrugated cardboard for sustainable fibre composite production - #BIOForm for short.

"Shaping the future, tackling tomorrow's changes today..."

ZEDC

Airbus opens new ZEROe development centre in Stade for innovative hydrogen technologies.

Current videos from the ZLP site in Stade

"Hydrogen Storage XL" the DLR Enersphere Approach
The HyStor project enabled the Process Technologies department of the Institute of Lightweight Structures to take the first steps towards a composite hydrogen tank. Starting with the design, initial concept ideas and production trials, a complete demonstrator was created. This has a length of 2.5 metres and a diameter of 3 metres. It was successfully deposited and cured using the research infrastructure of the ZLP Stade. This video gives an impression of the production process.

"Hydrogen Storage XL" the DLR Enersphere Approach

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"Hydrogen Storage XL" the DLR Enersphere Approach
The HyStor project enabled the Process Technologies department of the Institute of Lightweight Structures to take the first steps towards a composite hydrogen tank. Starting with the design, initial concept ideas and production trials, a complete demonstrator was created. This has a length of 2.5 metres and a diameter of 3 metres. It was successfully deposited and cured using the research infrastructure of the ZLP Stade. This video gives an impression of the production process.

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Contact

Prof. Dr. Martin Wiedemann

Director
German Aerospace Center (DLR)
Institute of Lightweight Systems
Lilienthalplatz 7, 38108 Braunschweig

Dr.-Ing. Daniel Stefaniak M.Sc.

Head of the ZLP Stade and head of department
German Aerospace Center (DLR)
Institute of Lightweight Systems
Department Production Technologies
Ottenbecker Damm 12, 21684 Stade

DLR site Stade

DLR site Stade
German Aerospace Center (DLR)
Ottenbecker Damm 12, 21684 Stade