Increasingly complex market requirements, desire for individuality and sustainability awareness have the same impact on developments as technological progress. We are actively involved in developing energy and resource efficient vehicle technologies, drives and production facilities.

The demand for powerful energy storage for the diverse drive mix of future electric vehicles is increasing. EDAG is working to integrate new generations of drives and energy storage systems for battery electric cars (BEV), plug-in hybrids (PHEV) and fuel cells (FCEV). Goals are higher power densities and avoidance of raw materials that are expensive and scarce and ethically problematic to procure. This also involves the question of how to integrate inductive charging technology into a vehicle or the road? The prerequisite and basis are our many years of experience in power electronics, battery technologies and battery management systems, e-machines and charging interfaces.

The concept for the Smart Factory is based on the production processes of the factory. Within this sphere of activity, a process landscape is created in which production and IT processes are efficiently aligned. The goal is to use resources effectively in order to operate the production system on all channels (buildings, manufacturing, logistics, IT) with optimal added value. Smart Factory means the intelligent linking of individual components such as e.g.:

  • Flexible, modularised production,
  • Individualised automation,
  • Proactive production monitoring and control (Smart Maintenance, Big Data Analytics),
  • Intelligent logistic systems,
  • Smart Building (BIM, modular building concepts, energetic optimisation).

EDAG is mainly involved in the following topics:

  • Employee relief through efficiency-enhancing tools,
  • Consulting and realisation concerning the introducing of IT, PM and service solutions as well as
  • energy management/simulation

In view of climate change and the increasing scarcity and increase in the cost of natural resources, improved energy and material efficiency is becoming increasingly important in production. Car manufacturers, suppliers and production equipment suppliers have top face this trend towards greater sustainability. 

One of EDAG's strengths is deriving and simulating operating strategies for electric drives in the overall system. In this context, we utilise our strengths in

  • Power electronics,
  • Battery technology and manufacturing,
  • E-machines and
  • Their interaction in the overall system.

Endurance tests of electric drive components are becoming increasingly competitive. Battery system developments, thermal designs, etc. not only require test know-how, but also special cyber-physical simulation skills as well as the associated software and hardware. 
At higher speeds, energy consumption is highly dependent on the aerodynamics of the individual vehicle. Optimising the aerodynamic design of vehicles can result in positive effects at increasing speed in terms of energy consumption, pollutants and noise emissions. For example, this applies for the air flow through the engine compartment in the passenger car sector, or the overall aerodynamic design in road freight transport, which leads to the controlled air flow around the truck. 

This requires the consistent expansion of our range of services in simulation as well as the associated requirement and design know-how.

The goal is to use smart power grids as an alternative to unnecessary power lines and to integrate electro-mobility into the holistic and user-oriented smart grid. To ensure grid stability with increasing electrification, input and output have to be balanced at all times. The intelligent coordination of charging processes via the Smart Grid and the adaptation to network availability is an important approach for our society and a challenge for the industry. EDAG is therefore concerned with grid integration and charging strategies for electro-mobility. In addition, we are developing the necessary components for charging infrastructures and vehicle system technologies.

Assessment of resource efficiency and/or the CO2 impact through appropriate methods in the product development and exploitation phase. The goal is the labelling of products. We are creating the basis for it:

  • Requirements for the ecological balance,
  • Calculation models for the ecological balance,
  • Software solutions for implementation,
  • Calculation of emissions in complete supplier value-added chains and motor vehicles.



We continuously develop know-how for the application of intelligent materials such as, for example, the integration of sensors and actuating elements into the surfaces of the interior and exterior:

  • Internal HMI: Interfaces, operating and comfort systems, office systems
  • External HMI: multi-functionality, security, headlamps, lights and lighting systems.

Our success factor is the close interdisciplinary interaction of design, electrics/electronics, body engineering, calculation and model buildiOur success factor is the close interdisciplinary interaction of design, electrics/electronics, body engineering, calculation and model building. In particular, this creates a completely new complexity, which can be managed by socio-technical systems. Success factor advanced systems engineering for value adding of tomorrow. 

Furthermore, we are not only concerned with the functional integration in the HMI, whereby added value can possibly be achieved in combination with economic advantages in space, mass, costs, number of components and joining operations - with easier handling and an improved user experience (UX).

In both phases of product development and the use of a vehicle (car, truck, rail, aircraft), there are many starting points for energy and material efficiency - in other words, for greater sustainability. 
In order to secure and expand the competitiveness and technological leadership of the German automotive industry, we are particularly pushing ahead by introducing cost, energy and material efficient manufacturing as well as processing technologies for lightweight vehicle construction. We can always achieve this by taking into account the entire process chain, worldwide production allies, large quantities and the availability of cost-effective materials. In addition to an expanded portfolio of modern steel grades, intelligent and functional semi-finished products for scalable and variation-intensive production methods up to extremely large quantities are in demand

EDAG is striving for lightweight design in mass production to be cost-driven and not purely technology-driven. The implementation of lightweight construction on a broad basis requires lightweight production technology with maximum economy. This particularly concerns vehicle fleets in the urban mass segment, which are already able to score LCA points due to an optimal product development phase, e.g. with steel-intensive lightweight construction at a comparatively short vehicle mileage and service life. 

Due to the (as yet) rather limited capacity for energy storage, the weight of the vehicle must be kept as low as possible to achieve driving characteristics and ranges acceptable to the consumer. Lightweight construction is one of the key technologies of future, efficiency-optimised and low-emission vehicle concepts.
The use of light-weight metal materials in mixed construction is still worthwhile, especially in premium vehicles with high mileage,. Although these can be slightly disadvantageous during the product development phase, they score throughout the long product usage phases due to the unequally higher weight advantage in an LCA. 

New materials and especially the light-metal-intensive mixed construction as well as multi-material systems find permanent access in the vehicle development and production. At the same time, its construction corresponding with the material
has to comply with the requirements for safety, dynamics, economy and function. They also include:

  • The illustration of efficient cycles for "strategic" materials, intelligent joining techniques and compounds in the material mix,
  • Adaptability as well as
  • Maintenance and repair concepts.

In addition to technology competence, high-quality simulation and modelling methods are important to us in the consideration of the overall system. 

Although carbon-intensive construction only plays a role in the market in exceptional cases, engineering competence is relevant among competitors for all types of high-performance vehicles. This concerns

  • Component design,
  • Design know-how,
  • Tool technology
  • Production planning for carbon and fibre composites.

Among other things, our research activities are aimed at sustainably reducing energy consumption during product manufacture and usage with innovative manufacturing and processing technologies for the application of future-oriented lightweight materials (fibre composites and multi-material systems). This permits:

  • Cost reduction in manufacturing processes and
  • new CAE intensive design tools for load-adapted design of highly functional lightweight components.

In order to cope with automotive requirements, the market requires a variety of highly functional products made of high-performance plastics. This also applies to application technology, simulations and manufacturing know-how. We can develop products significantly with industry experts. Hybrid lightweight construction is a key technology to meet the growing challenges in the automotive industry. The use of metal-plastic composites combines the advantages of two classes of materials in one hybrid component. Developments in research factories, such as the Wolfsburg automobile location in OHLF or Chemnitz, MERGE clusters for hybrid lightweight construction, are gauged and assessed as new scientific results.

Bioplastics can be produced from a variety of plant-based raw materials. The most important raw material suppliers are wood (cellulose and lignin), cereal plants and potatoes (starch), sugar cane and sugar beet (sugar) and oil plants (vegetable oils). In order to be able to produce modern materials from natural fibres, a binder or a plastic matrix is needed for their solidification. Traditionally, animal and vegetable glues, adhesives and resins have been used. Today, the industry uses mainly petrochemical plastics. Alternatively, bio-based plastics are becoming increasingly important in this context. Advantages include ecological sustainability and global market independence. EDAG is committed to evaluating and helping shape these technologies in the industry. 

Functional effects of new materials, in particular on the vibration behaviour of vehicle structures, can be compensated with adaptronic
approaches. Innovation drivers are actuators, motors or sensors. 


Dr. Jan Leilich

Head of Innovations

p +49 661 6000-80093 



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