OEM& LIEFERANT Special-Edition „Autoregionen International“. Ausgabe 02/2026
Mehr Service. Mehr Flexibilität. Mehr für Dich. Hedin Automotive Südwest GmbH Untertürkheimer Str. 1 66117 Saarbrücken Idar-Oberstein | Landstuhl | Kusel Kaiserslautern | Mannheim | Neunkirchen Saarbrücken | Saarlouis | St. Wendel Tel.: 0681 5070 Hedin Automotive Retail GmbH August-Herrmann-Straße 2 67655 Kaiserslautern Landstuhl | Idar-Oberstein | Mannheim Saarbrücken | Dresden Land Rover Tel: 0631 3426 - 1310 Hyundai Tel: 0631 41418 - 0 www.hedinautomotive.de Hedin Automotive emobility GmbH Brebacher Landstraße 1 66121 Saarbrücken Tel.: 0681 968080 Mannheim | Schwetzingen | Kaiserslautern Saarbrücken | Dresden | Görlitz
3 The German automotive industry is facing the most profound transformation in its history. The shift from combustion engines to electric powertrains is only one part of this transformation. The car itself is undergoing a fundamental change: what was once a mechanically dominated product is increasingly becoming a platform driven by software, data, and AI. The software-defined vehicle is a prime example of this transformation. Central computing architectures, over-the-air updates, and software development are changing a vehicle’s technology and lifecycle. Artificial intelligence adds another dimension: The vehicle is no longer meant to simply execute commands, but to understand contexts and increasingly take on tasks independently. At the same time, the balance of power in international competition is shifting. Chinese manufacturers, in particular, are rapidly combining electromobility, batteries, software, and AI. This is resulting in a competitive model that is forcing European manufacturers and suppliers to rethink their strategies. Our industry is well-positioned: strong brands, technological excellence, industrial manufacturing capabilities, and the highest level of safety expertise. But these strengths must be combined with a new sense of speed. The key question, therefore, is not how quickly individual technologies will gain traction. What matters most is who can turn technology into competitive products and new business models more quickly. The future of the automotive industry depends on this. In this issue of “OEM & Supplier,” dear readers, you will once again gain insight into the competitiveness and innovative capacity of the German automotive and supplier industries, as well as their contractors and service companies. We would like to thank everyone involved for their excellent and trusting collaboration on this magazine. You are cordially invited to contribute to the next issue, which is scheduled to be published in the spring of 2027. Your editorial team Elisabeth Klock and Astrid Schafmeister Visit our trade press portal www.oemundlieferant.de And become a member of the LinkedIn specialist group LinkedIn-Gruppe OEM&Lieferant Dear readers, Editorial Germany‘s Automotive Transformation Deutschlands Automobil- industrie im Wandel Liebe Leserinnen und Leser, die deutsche Automobilindustrie steht vor dem tiefgreifendsten Wandel ihrer Geschichte. Der Umstieg vom Verbrennungsmotor auf den Elektroantrieb ist dabei nur ein Teil der Transformation. Das Auto selbst wandelt sich grundlegen … Weiterlesen: https://t1p.de/vxr8h Note: This text was generated using AI and has been edited. Astrid Schafmeister Elisabeth Klock
Dr. Georg Wagner, NTC Nano Tech Coatings GmbH, Tholey (Saarland) 8 Manuel Staub, NTC Nano Tech Coatings GmbH, Tholey (Saarland) 8 Henning Kemper, Senior Specialist Editor, IPG Automotive 10 Joerg Zumkley, Media Relations Global, Surventis 16 Mathias Behounek, Executive Director, SAFELOG GmbH 18 Patrick Fischer Riegert, imds professional 19 Andreas Blecher, Team Manager Marketing, EJOT SE & Co. KG 14 Christian Düsl, Projektleiter, SUSI&James, Mannheim 20 Medina Hodzic, Referentin für digitale Kommunikation, SUSI&James, Mannheim 20 Thomas Ohde, Director Operations, SUSI&James, Mannheim 20 Lena Mårtensson, Senior Marketing & Communication Officer, Luxinnovation GIE 6 Bild: © Luxinnovation/Marion Dessard Authors and Interviewees Please click on the respective page number to open the author‘s article Autoren/-innen und Interviewpartner/-innen Bitte klicken Sie auf die jeweilige Seitenzahl, um den Beitrag des Autors/in zu öffnen
5 Editorial 3 Bolt, Pony.ai and Stellantis test 6 self-driving mobility in Luxembourg By Lena Mårtensson, Senior Marketing & Communication Officer, Luxinnovation GIE From Inner Tubes to Fins: Functional 8 Coatings for Heat Exchangers By Dr. Georg Wagner and Manuel Staub, NTC Nano Tech Coatings GmbH, Tholey (Saarland) Reproducible Use of Real 10 Sensor Data in the Lab SensFlow leverages real ADAS and AD scenarios for reproducible HIL tests By Henning Kemper, Senior Specialist Editor, IPG Automotive Future-oriented fastening solutions 14 for electromobility By Andreas Blecher, Team Manager Marketing, EJOT SE & Co. KG Low-bake innovation for the next 16 generation of energy-efficient paintshops By Joerg Zumkley, Media Relations Global, Surventis „Lease mobile robots instead of 18 purchasing them – and save money from day one.“ Interview with Mathias Behounek, Executive Director of SAFELOG GmbH imds professional Interview with Patrick Fischer Riegert 19 from imds professional on the PPWR Wenn Qualität in die Lieferkette wandert, 20 wird 8D zum Steuerungsinstrument Von Thomas Ohde, Director Operations, Christian Düsl, Projektleiter, und Medina Hodzic, Referentin für digitale Kommunikation, SUSI&James, Mannheim Company Presentations/ Firmenpräsentationen/ Böllhoff 22 SUSI&James GmbH 24 Walter Werner GmbH 25 Metallveredelung Experts /Experten 26 Legal notice/Impressum 12 Advertisements/Anzeigen Hedin Automotive GmbH U2 OEM & Lieferant 7 EJOT SE & Co. KG 9 SURVENTIS 11 SAFELOG 13 IPG Automotive 17 IZB Internationale Zuliefererbörse Wolfsburg 21 BÖLLHOFF 23 NTC Nano Tech Coatings GmbH 27 Luxinnovation U4 Inhalt/Content
6 Bolt, Pony.ai and Stellantis test self-driving mobility in Luxembourg By Lena Mårtensson, Senior Marketing & Communication Officer, Luxinnovation GIE Why did Bolt and its partners choose Luxembourg for their autonomous vehicle pilot? Marc Naether, Head of Public Policy BeNeLux, explains the regulatory and ecosystem advantages, including Luxinnovation’s support. A regulatory head start for autonomous vehicle pilots In June 2026, Estonia-based European mobility platform Bolt, autonomous driving technology company Pony.ai and automaker Stellantis announced the launch of an autonomous mobility pilot programme in Luxembourg. The objective is to test the technologies and operational processes required to support safe driverless mobility in cities. “We will test the whole ecosystem needed: vehicle deployment, platform integration, fleet operations and regulatory coordination,” says Marc Naether, Head of Public Policy BeNeLux at Bolt, who is directly involved in establishing the company’s operations in Luxembourg. Bolt has been in contact with Luxembourg authorities for several years on a variety of mobility-related topics. However, discussions around autonomous mobility gained momentum following an event in Brussels in autumn 2025, where Mr Naether met Anthony Auert from Luxinnovation. During the meeting, he learned about Luxembourg’s ambition to become the first European country to roll out automated driving nationwide by 2028. A few months later, Bolt and its partners decided to launch their project in the Grand Duchy. “Luxembourg is one of the few countries that have a favourable regulatory regime for this type of autonomous vehicle pilot project,” Mr Naether explains. “We will start by operating under the scientific testing regime for autonomous vehicles (a regulatory framework allowing companies to operate autonomous vehicles for research purposes on public roads [Ed.]), and are currently waiting for our permit to be granted. Next year, the Luxembourg government is expected to adopt a new law allowing the commercial deployment of self-driving vehicles including autonomous taxis. This would allow us to take the next step.” Why Luxembourg is becoming Europe’s autonomous mobility testbed The initiative is part of Bolt’s ambition to accelerate the transition from privately owned cars to shared mobility. At the launch of the project, Markus Villig, founder and CEO of Bolt, pointed out that autonomous mobility technology is transforming transportation around the world, and that Bolt wants to be at the forefront of scaling this technology in Europe. Pony.ai, which chose Luxembourg as the base for its European expansion in 2024, contributes to the project with its autonomous driving technology and operation experience. Stellantis provides its technical platform enabling driverless operations as well as its vehicle engineering and expertise in manufacturing. “We decided to use Luxembourg as our ‘living lab’ to develop our autonomous driving plans,” says Mr Naether. “Based on the research and pilot testing we will do here, we will develop a product including driverless vehicles that we can scale elsewhere in Europe.” Three reasons Bolt chose Luxembourg for its autonomous driving pilot When asked why Luxembourg stood out among potential locations, Mr Naether is specific: Image: © BOLT
• The suitable regulatory framework – including a scientific testing regime that allows pilot operations before full commercial legislation is in place • A clear political ambition – Luxembourg aims to become the first European country to roll out automated driving nationwide by 2028, a target that signals genuine longterm commitment rather than regulatory experimentation • The good testing conditions – a varied terrain with urban and rural roads, flat and hilly landscapes and a mild climate, covering the range of driving scenarios that a vehicle must handle reliably before any commercial rollout He appreciates the smooth interactions with the ministries of Mobility and of the Economy and with Luxinnovation. “They have supported and guided us in the launch of this project.” He also mentions that regulations and political ambitions don’t always align in all jurisdictions. “But in Luxembourg, the government shows real motivation to attract companies that invest in autonomous driving. Luxinnovation is also a very active partner and keeps suggesting new potential partners that we can interact with.” Mr Naether mentions Luxembourg’s diverse, international population as an advantage. “At a later stage, this will give us access to very different types of potential users. In addition, the fact that Luxembourg is home to several European institutions and frequently hosts international meetings means that we will be able to showcase our work to officials travelling in and out of the country.” Bolt’s next steps for autonomous driving in Luxembourg Bolt recently incorporated its subsidiary in Luxembourg. The company is now focusing on the regulatory approval process and on solving the last operational issues so that the project can start as soon as possible. To start its activities, it has rented space in the Technoport incubator at Luxembourg’s AutoMobility Campus north of the capital, where Pony.ai is located as well as several other mobility companies. The joint initiative with Pony.ai and Stellantis is Bolt’s first autonomous mobility project, representing a milestone in its plans to scale driverless services across European cities. By aiming for driverless readiness by the end of the pilot, the partners are using Luxembourg not just as a testing ground, but as the blueprint for the future of European urban transport. Luxinnovation: Catalysing innovation through collaboration The project also illustrates the broader role played by Luxinnovation in strengthening Luxembourg’s innovation ecosystem. Acting as a facilitator between companies, research organisations and public authorities, Luxinnovation helps national and international businesses identify collaboration opportunities, build innovation partnerships and accelerate the development of new technologies. In addition to supporting the establishment of strategic projects such as the Bolt-Pony.ai-Stellantis initiative, the agency assists companies throughout their innovation journey, including the identification of suitable partners, the structuring of collaborative R&D projects and access to national research, development and innovation (RDI) funding schemes. “By combining ecosystem expertise with funding guidance, Luxinnovation contributes to creating favorable conditions for innovative projects to be developed, tested and scaled from Luxembourg”, explains Anthony Auert, Manager Mobility ‑ Business Relationship Management at Luxinnovation. https://luxinnovation.lu Wilhelm-Schrohe-Str. 2 · 55128 Mainz · Phone +49 157 50153533 · info@klock-medienpartner.de · www.oemundlieferant.de Digital trade magazine for the automotive and supplier industry. The next issue will be published in March 2027. OEM&Lieferant available anytime, anywhere. Join the LinkedIn professional group OEM&Lieferant OEM& LIEFERANT Netzwerk Automotive - Innovationen. Konzepte. Lösungen. Automotive network. Innovations. Concepts. Solutions. Visit our trade press portal for the automotive and supplier industry www.oemundlieferant.de
8 From Inner Tubes to Fins: Functional Coatings for Heat Exchangers By Dr. Georg Wagner and Manuel Staub, NTC Nano Tech Coatings GmbH, Tholey (Saarland) Heat exchangers are key components in automotive thermal management. They must reliably transfer heat while remaining durable against media, temperature fluctuations, and operational stresses. Functional coatings can play a significant role here in protecting components, improving system cleanliness, and stabilizing performance over the long term. Conditions inside oil coolers are demanding. The oil dissipates heat and is in constant contact with the inner tube materials. Over extended periods of use, chemical influences can cause metal ions to be leached from the substrate and transferred into the medium. In practice, this can lead to a change in viscosity or even gelation, among other issues. The inner tube coating, specially developed by NTC and widely adopted in industry, acts as a diffusion barrier in this case. It prevents direct contact between the oil or cooling medium and the base material. Due to the very thin coating thickness, heat transfer is maintained. In this way, the coating contributes to the heat exchanger’s resistance to the medium, component cleanliness, and longevity. The fins on air conditioning heat exchangers also place special demands on the surface. The heat exchanger is installed in the vehicle’s air conditioning system; however, the fins form the outer surface of the component that is exposed to the airflow. There, moisture, condensate, dust, and organic residues can lead to deposits and affect the system’s function and hygiene. This is where the hydrophobic “Easy-toClean” coatings developed by NTC come Von Innenrohren bis Lamellen: funktionale Beschichtungen für Wärmetauscher Wärmetauscher sind zentrale Bauteile im automobilen Thermomanagement. Sie müssen Wärme zuverlässig übertragen und gleichzeitig dauerhaft gegen Medien, Temperaturwechsel und betriebsbedingte Belastungen beständig bleiben. Funktionale Beschichtungen können hier einen wichtigen Beitrag leisten, um Bauteile zu schützen, die Sauberkeit des Systems zu verbessern und die Leistungsfähigkeit langfristig zu stabilisieren … Weiterlesen: https://t1p.de/cn909 Bild: © NTC, KI-modifiziert into play. They reduce the adhesion of moisture and residues. As a result, the surface can remain clean longer, and microbial-induced odor formation is also reduced. The adhesion of the coating is crucial here. An intensive bond—or interlocking—with the substrate creates a durable connection, which is particularly important for thin functional coatings in automotive applications. NTC Nano Tech Coatings GmbH thus positions itself as an experienced partner for functional heat exchanger solutions in vehicles: from internal diffusion barriers in oil coolers to hydrophobic easy-to-clean coatings for finned heat exchangers. www.ntcgmbh.com www.ntcgmbh.com/en/products www.ntcgmbh.com/en/contact Bild: © NTC, KI-modifiziert
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10 Reproducible Use of Real Sensor Data in the Lab SensFlow leverages real ADAS and AD scenarios for reproducible HIL tests By Henning Kemper, Senior Specialist Editor, IPG Automotive Rare traffic situations, changing software statuses and high sensor data rates make the validation of modern ADAS and AD functions extremely difficult. An edge case recorded once is only valuable when it can be replayed, analyzed and evaluated under reproducible boundary conditions in the lab. This is where SensFlow from IPG Automotive offers support. The modular software suite injects recorded sensor and vehicle bus data deterministically into electronic control units (ECUs) and thus creates a realistic test basis for hardware-in-the-loop environments, without having to perform the respective test case on the road again. Targeted reuse of real-world data Due to the increasing performance of automated driving functions, the effort in their validation rises as well. Sensor setups become more heterogenous, interfaces more complex and the amount of data to process grows. At the same time, safety-relevant situations in real-world traffic occur infrequently or cannot be reproduced as desired. OEMs, suppliers and development teams thus have a clear requirement: They need to be able to feed real measurement data back into the ECU environment in a controlled manner. SensFlow supports this process through a time-consistent reproduction of recorded sensor data and vehicle bus information. In this way, perception, localization and overall functionality can be assessed under controlled laboratory conditions. Deterministic replay with exact timing What matters is not only the replay of data, but also the exact moment at which they arrive at the ECU. SensFlow is designed for the deterministic replay of recorded sensor data streams, including radar, Deterministic replay of recorded sensor and vehicle bus data for reproducible ADAS and AD validation ultrasonic, camera and lidar. In addition, CAN and Automotive Ethernet communication can be reproduced synchronously. Exact time stamp synchronization ensures that all input data are available in the right order and at the right time. SensFlow is therefore ideal for open-loop tests. The function under test receives recorded or specifically provided input data, without needing a closed simulation feedback loop. Perception algorithms, sensor fusion and decision-making logics can hence be evaluated reproducibly. Especially in early development stages, this approach facilitates quick software comparisons, benchmarking and the targeted analysis of individual functions before full system integration becomes necessary. In this context, the synchronized coordination of all data sources is decisive. If raw sensor data, vehicle bus information and image data are reproduced in a time-consistent manner, an exact representation of the recorded driving situation is created at the ECU input. It lays the foundation for reliable lab results and a sound evaluation of software changes. Flexibility for different ECU environments SensFlow’s modular architecture can be adapted to a variety of ECU architectures, sensor layouts and data formats. Therefore, the software supports both individual ADAS functions and complex AD systems with multiple sensor sources and high data rates. Standardized data formats and defined replay processes enable consistent data management. Development teams can Image: © Andrey_Lobachev/Adobe Stock; Editing: IPG Automotive
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12 reuse measurement data, streamline test processes and compare results across different software statuses more easily. The manual integration effort decreases, and, at the same time, the recurring validation tasks are executed in a more organized way. Increased efficiency in testing and troubleshooting The practical benefit lies in the precise reproducibility, which enables running critical scenarios multiple times, comparing software statuses with each other and pinpointing faults under stable conditions. As a result, test cycles get shorter and the validity of results increases. This approach is especially effective with complex perception and localization functions. Tests become more independent from prototypes, weather conditions or rarely occurring traffic situations. At the same time, the real-world data basis necessary for a sound function evaluation is maintained. Integration into existing toolchains SensFlow was designed for seamless integration into already existing development and test environments. Combined with the CarMaker product family, the replay approach can be extended to include closedloop validation. This enables development teams to merge real measurement data and virtual scenarios into a continuous validation strategy. SensFlow synchronizes the recorded data of various sensor and bus systems Raw data from camera, radar and lidar sensors as well as vehicle bus data via CAN or Ethernet are injected into ECUs. Existing HIL environments can hence be extended by adding real-world driving scenarios without having to rebuild the test infrastructure. In practice, SensFlow supports both real-world test drives and simulation: Real measurement data provide the input basis, replay enables reproducible use and virtual tests allow for a systematic expansion. This results in a scalable validation process that supports reproducible tests across the entire development process. Conclusion: Real-world data become a reproducible test basis Reproducibility is a prerequisite to validate automated driving functions. SensFlow enables the deterministic reproduction of real sensor and vehicle bus data, the test of software statuses under similar conditions and the targeted analysis of faults. Therefore, sensor data replay becomes a reliable building block for modern ADAS and AD validation. Development teams can use real edge cases reproducibly in the lab, shorten iteration cycles and evaluate software changes under comparable conditions. https://www.ipg-automotive.com/ solutions/product-portfolio/sensflow Image: © IPG Automotive Impressum Verlag und Herausgeber: VEK Verlag Inhaberin: Elisabeth Klock Wilhelm-Schrohe-Str. 2, 55128 Mainz Telefon +49 157 50153533 info@klock-medienpartner.de www.klock-medienpartner.de Redaktion: Elisabeth Klock (v.i.S.d.P.), Chefredaktion Birgit Aigner, freie Journalistin Astrid Schafmeister, freie Journalistin Lektorat: Clive Davis Anzeigenleitung und -verkauf: Elisabeth Klock Telefon +49 157 50153533 Titelseite: Christopher Koster Fotosatz und Onlineausgabe: Grafik-/Webdesign Bauer www.grafik-bauer.de Weitere Mitarbeiter dieser Ausgabe: Günther Gaimer Titelbild: Zur Gestaltung des Titels benutzten wir Illustrationen und Fotos von: • Dmitry Kalinovsky/shutterstock.com • Summit Art Creations/shutterstock.com • Gorodenkoff/shutterstock.com • 3Dsss/shutterstock.com • Sylverarts Vectors/shutterstock.com • ConnectVector/shutterstock.com Ausgabe 2/2026 Copyright: Verlag Elisabeth Klock Das Werk wurde mit größtmöglicher Sorgfalt und nach bestem Wissen erstellt und erhebt keinen Anspruch auf Vollständigkeit. Für die Richtigkeit der Veröffentlichung kann trotz sorgfältiger Prüfung weder vom Verlag noch von der Redaktion eine Haftung übernommen werden. Namentlich gekennzeichnete Beiträge geben die Meinung des Autors bzw. des Unternehmens wieder. Der Verlag und die Redaktion machen sich diese Fremdbeiträge nicht zu Eigen. Die Unternehmen sind für das zur Verfügung gestellte und veröffentlichte Bild- und Grafikmaterial im Werk verantwortlich, insbesondere ob das Material frei von Rechten Dritter ist. Der Verlag hat die ausschließ- lichen Nutzungsrechte zur Verwertung der angenommenen und veröffentlichten Beiträge und Artikel. Nachdrucke, auch auszugsweise, sind nur mit vorheriger Zustimmung des Verlages möglich. Alle Texte, Bilder und Grafiken sowie deren Anordnung unterliegen dem Urheber- und Leistungsschutzrechts. Für direkte oder indirekte Verweise auf fremde Internetseiten („Links“), die außerhalb des Verantwortungsbereiches des Verlags liegen, übernimmt der Verlag keine Haftung. Für die Inhalte und Richtigkeit der bereitgestellten Informationen auf den fremden Internetseiten ist der jeweilige Anbieter verantwortlich. Der Verlag macht sich den Inhalt dieser fremden Internetseiten nicht zu Eigen.
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14 Future-oriented fastening solutions for electromobility By Andreas Blecher, Team Manager Marketing, EJOT SE & Co. KG In the emerging field of electromobility, EJOT focuses on developing and producing highly specialized functional and fastening elements tailored to the unique demands of high-voltage batteries and power electronics. For these complex projects, EJOT leverages advanced manufacturing technologies and robust application engineering support to deliver customized solutions to its customers. High-voltage battery The drive battery is the energy source of an electric vehicle and, depending on its design, comprises multiple battery modules interconnected by solid copper conductor rails. The objective is to establish a durable electrical connection with minimal contact resistance between conductors. This connection endures particularly challenging conditions, such as vibrations during driving and temperature fluctuations from charging and discharging cycles. To ensure the integrity of the screw joint and its resistance to vibrations, customers can utilize simulation software and benefit from the comprehensive support of EJOT’s in-house APPLITEC laboratory. Here, the clamp loads of the connection are evaluated under varying temperatures and vibration tests simulate operational stresses. Another critical requirement, which results from the high electrical load on the connection, is the necessary touch protection of the screw. Although the screw itself is not an electrical conductor, it can become conductive upon contact, posing potentially severe risks. To address this, EJOT combines its expertise in plastic injection molding with metal forming capabilities. This results in screws encapsulated with plastic at both the head and tip (Fig. 1). The plastic overmolding is meticulously designed to ensure maximum safety during operation, maintenance and repairs. To achieve the required electrical insulation, EJOT can also design the required clearance and creepage distances. Furthermore, each overmolded screw undergoes a 100 % dielectric strength test at 4,000 volts during production to ensure optimal safety. To seal the battery housing of an electric vehicle, the battery cover is fastened onto the hollow aluminum profile of the battery frame. An established technology for this demanding joining task is the so-called “Flow Drill Screw” (FDS®), originally developed for body-in-white structures (Fig. 2). A significant challenge is ensuring a reliable seal to protect the sensitive internal components of the battery from harsh environmental conditions. To achieve a durable and secure VOLTtec® Insulated Screw for high-voltage applications ● Ensures electrical connectivity ● Provides electrical insulation ● Offers vibration resistance FDS® with aluminum sealing washer ● Head-side sealing function ● Joining process with one-sided accessibility ● Facilitates easy disassembly and recycling Fig. 1 Fig. 2
15 sealing function, EJOT has developed a FDS® screw equipped with a combined aluminum sealing washer. The sealing washer used by EJOT meets the stringent tightness requirements, even under the 24-hour climate change test required by the automotive industry. A notable feature of the FDS® technology is its suitability for applications with single-sided access to the joint. Since fastening can be done directly without pre-drilling the component, preparatory steps like pre-drilling or thread cutting are unnecessary. This eliminates tolerance issues associated with through holes and screw-in holes. The clearance-free fit between the screw-in part and the screw thread, achieved during flow drilling, results in high loosening torques and enhanced vibration resistance. Consequently, additional security elements are redundant. As the FDS® screw connection is detachable, the battery box can be easily opened and closed for maintenance, repair or recycling purposes. Repeat fastening is also feasible with metric screws, thanks to compatible thread geometry. Power electronics Power electronics are at the heart of an electric vehicle’s powertrain. The inverter, for instance, transforms the battery’s DC voltage into AC voltage to power the electric motor. It ensures precise control of the electric motor, contributing to a dynamic and efficient driving experience. Achieving exceptional power density and reliability are the primary development objectives for OEMs. For the demanding application field of power electronics, EJOT offers a broad product portfolio tailored to specific customer requirements. To attain a compact and efficient design that integrates multiple functions within single housing, inverters often feature stacked circuit boards. To ensure proper functionality, these PCBs must be electrically isolated from one another. This isolation is achieved using spacers inserted between the individual boards (Fig. 3). The VOLTtec® PCB Spacers comprise an ALtracs® Xt screw, designed with a plastic overmold on the head. This metal-plastic combination ensures a precisely defined distance between the PCBs. During assembly, the first PCB is fastened into the die-cast aluminum using the ALtracs® Xt self-tapping thread. Subsequently, the next circuit board is directly fastened into the plastic overmold on the head using an EVO PT® screw. The high technical demands of this application are further underscored by the customer’s requirement for a dielectric strength of 4 kV, both between PCBs and the screw connections. This dielectric strength is rigorously tested on standardized production cells within the EJOSYST® area. The PCB Spacers developed by EJOT not only ensure safe electrical decoupling of the circuit boards but also contribute to a compact and efficient design. Copper components are used in the power electronics of electric vehicles to reliably conduct high currents and effectively dissipate the generated heat. For high-voltage applications (Fig. 4), EJOT manufactures high-precision cold-formed copper parts through a multi-stage cold forming process, marketed under the EJOFORM® brand. This technology transforms a wire section into a customized cold-formed part over several forming stages. Compared to the commonly used turned parts, cold forming offers cost-effective and resource-efficient large-scale production, high material utilization and enhanced component properties. The precisely manufactured EJOFORM® copper components can be further refined by various processes. Meeting the highest standards for technical cleanliness, burr-free finishes, dimensional accuracy, shape or position tolerances and surface precision, these complex parts can also be machine finished at EJOT. The aim is to provide customers with a flawless result from a single source through the optimal integration of all process steps. EJOT upholds this high standard across all electromobility projects. Beyond technical expertise, close and collaborative cooperation with customers is pivotal to success. www.ejot.com/industry VOLTtec® PCB Spacer for stacked boards ● Ensures dielectric strength ● Features self-tapping thread for light metals ● Incorporates plastic-molded head as screw-in point EJOFORM® copper contacts with high electrical conductivity ● Economical due to material-saving technology ● Fully aligned with application requirements ● Meets highest tolerance requirements Fig. 3 Fig. 4 Images: ©EJOT
16 Low-bake innovation for the next generation of energy-efficient paintshops By Joerg Zumkley, Media Relations Global, Surventis Automotive OEM paintshops are among the most energy-intensive areas in vehicle manufacturing, accounting for more than 60% of a factory’s total energy consumption. As the industry moves toward lower emissions, electric vehicles and more sustainable production, reducing energy demand in coating operations has become a key lever for decarbonization. Surventis is developing an integrated low-bake solution designed to lower curing temperatures in OEM paintshops while maintaining the high-quality standards required in automotive coating processes. Conventional automotive coating processes typically require curing temperatures of around 140 °C. The low-bake approach under development at Surventis aims to reduce this to approximately 80–90 °C, helping cut energy use, CO₂ emissions and operating costs. Based on evaluations using GLASS, Surventis’ proprietary paintshop life-cycle assessment tool, lowering oven temperatures by up to 60 °C shows the potential for: • up to 30% energy savings in the paintshop, • u p to 20% lower CO₂-equivalent emissions, • and up to 30% lower energy-related operating costs per vehicle, depending on the paintshop setup. These assessments provide an important reference point for the sustainability impact of low-temperature curing, while further validation and customer-specific trials continue. Integrated thinking across body and bumper coating A key development direction is the integration of body and plastic parts, such as bumpers, into a single coating process. Coating both together in one line can simplify paintshop layouts, improve color matching and reduce complexity. This process perspective goes beyond individual material innovations. It looks at how coating steps, materials and components interact in a low-temperature environment, from sealants and primers to basecoats, clearcoats and plastic substrates. Graphic: © Surventis This creates additional potential for OEM paintshops: • >50% CAPEX savings by eliminating a separate bumper line. • > 60% lower VOCs in bumper coating by replacing solvent-borne with waterborne basecoat and eliminating conductive primer. Collaboration along the value chain Meaningful reductions in curing temperature require not only reformulating coatings. They depend on close collaboration across the automotive value chain, including material suppliers, equipment partners, and OEMs. Surventis works closely with partners in areas such as sealant systems and plastics materials to ensure all components are compatible with lower-temperature processes and perform reliably under real paintshop conditions. This holistic approach aligns materials, processes, and equipment to unlock both economic benefits and sustainability gains. Value driven efficiency for future paintshops Low-bake technology is more than a technical adjustment. It represents a pathway toward more energy-efficient and economically viable automotive production. As OEMs pursue decarbonization targets, solutions that combine environmental benefits with operational efficiency will become increasingly important. While Surventis’ integrated low-bake solution is still under development, early assessments underline its potential to support the next generation of eco-efficient paintshops and help customers reduce emissions, energy use and process complexity. www.surventiscoatings.com
Solutions for Virtual Vehicle Development SensFlow – Turn Real Drives Into Repeatable Tests. www.ipg-automotive.com Learn more
18 „Lease mobile robots instead of purchasing them – and save money from day one.“ Interview with Mathias Behounek, Executive Director of SAFELOG GmbH Automation projects require significant capital, and purchasing mobile robots can be costly, which deters many companies. SAFELOG, in collaboration with CHG-MERIDIAN, offers a solution: a leasing model for mobile robots. This approach eliminates the need for pre-financing with own funds, offering a more flexible and secure financial option for the clients. Mathias Behounek, Executive Director at SAFELOG, explains why this is a significant development for many companies. Mr. Behounek, the advantages of automation solutions are evident. What are the reasons why many companies still decide against implementing them? It is important to distinguish between technical feasibility and economic efficiency. In brownfield environments, structural challenges often arise during the conversion of existing buildings and halls for automation solutions. In many cases, inadequate infrastructure necessitate costly renovations. It is essential to consider these costs in addition to the investment costs of purchasing the vehicles. Consequently, many companies are reluctant to proceed. The decision to implement an automation project depends on the return on investment (ROI). What solution does SAFELOG offer for this problem? In partnership with CHG-MERIDIAN, we provide our customers with the option to lease mobile robots. This offer includes not only the purchase of the vehicles but also optional peripherals, such as transfer stations and charging management. Additionally, software, project management, and commissioning costs can be included in the rate. CHG-MERIDIAN is a leading international leasing company. Could you please explain how this collaboration came about? The impetus for this change originated from market forces. Several customers have inquired about leasing or rental solutions due to the unpredictable nature of market development. CHG-MERIDIAN also expressed interest in entering the field of mobile robotics and approached us. The collaboration is proceeding smoothly. The capital required to implement an automation project with mobile robots is a significant factor that sometimes deters companies from pursuing such endeavors. Mathias Behounek is Executive Director of SAFELOG GmbH Images: © SAFELOG GmbH Currently, between 10 and 20 percent of our projects are being implemented using a leasing model.
19 Company Contact SAFELOG GmbH Henleinstr. 4 85570 Markt Schwaben strunz@safelog.de What are the primary benefits of the leasing offer? The primary benefit is that customers are not required to invest any of their own funds prior to the initiation of an automation project. CHG-MERIDIAN handles all pre-financing, including down payments. The initial leasing installment is not due until after project acceptance. This approach eliminates all initial capital expenditure. Additionally, CHG bears the residual value risk, which positively affects the installment amount. Consequently, our leasing offer substantially reduces the customer‘s financial expenditure, allowing them to swiftly begin realizing a return on investment (ROI). Could you please clarify the immediately ROI? As soon as the project is approved, regular operations commence, offering the customer savings due to more efficient processes or reduced personnel costs. This is also when the lease payments begin. In practice, this means that the monthly savings often exceed the lease payments. The contract is concluded with CHG-MERIDIAN AG? How long does it run for, and how much are the monthly payments? Yes, the leasing contract is directly concluded with CHG-MERIDIAN. The standard duration is between 36 and 60 months, with the option to customize. The monthly payments will depend on several factors, including the total investment volume and the ratio between hardware and software components. The desired contract term and the creditworthiness of the lessee also influence the final payment. At the conclusion of the initial term, customers have the option to return the mobile robots to CHG and transition to more recent models. Alternatively, the existing lease agreement can be extended to ensure the continued use of the current fleet. It is also possible to purchase the vehicles. The choice between these options depends on the customer‘s individual requirements and strategic orientation. Thank you very much Mr. Behounek. The interview was conducted for OEM&Lieferant: Alexander Strunz, Manager PR & Communications, SAFELOG Video CHG-MERIDIAN AG Powering Industrial Growth https://t1p.de/zx1ql www.safelog.de CHG-MERIDIAN AG Robotik, Maschinen und Automation https://t1p.de/hrb0b SAFELOG GmbH Finanzierung und Leasing von mobilen Transportrobotern https://t1p.de/1royy imds professional Interview with Patrick Fischer Riegert from imds professional on the PPWR The European Packaging and Packaging Waste Regulation (PPWR) entered into force on 11 February 2025 and will generally apply directly in all EU Member States from 12 August 2026. However, many of its specific requirements will be phased in over the following years. But which types of packaging are affected, which companies need to take action, and what exactly will they need to do? Product compliance expert Patrick Fischer Riegert from imds professional answers these and other key questions. What is the PPWR and what are its main objectives? For me, the PPWR is above all a clear signal from the EU: in the future, packaging should not only protect products effectively and look appealing, but also become significantly more sustainable. The regulation aims to reduce packaging waste, use fewer materials, and keep valuable resources in circulation for longer. For companies, this means rethinking packaging. It should not be viewed merely as a compliance obligation, but also as an opportunity to improve processes and demonstrate responsibility in a visible way. What will change for companies from 12 August 2026? In my view, 12 August 2026 marks the starting point for practical implementation. From that date, the PPWR will generally apply directly across all EU Member States. Companies will need a much clearer understanding of the packaging they use, how it is designed, and which requirements already apply. They will also need to determine their … Read more https://t1p.de/vkeb7 Patrick Fischer Riegert Image: © private Image: AI-generated
20 Qualitätsmanagement · Automobilzulieferer Wenn Qualität in die Lieferkette wandert, wird 8D zum Steuerungsinstrument Von Thomas Ohde, Director Operations, Christian Düsl, Projektleiter, und Medina Hodzic, Referentin für digitale Kommunikation, SUSI&James, Mannheim KI-gestützte Bewertung von 8D-Reports soll Zulieferern und OEMs helfen, Reklamationsprozesse schneller und konsistenter abzuwickeln, ohne die Daten aus der Hand zu geben. Einige chinesische Hersteller von Elektroautos verfolgen bei der Produktion einen auffällig anderen Ansatz als die etablierte Automobilindustrie: Sie setzen auf eine sehr hohe vertikale Integration und stellen einen Großteil ihrer Komponenten selbst her. Damit ist ihre Qualität deutlich weniger von einer externen Lieferkette abhängig. Dieser Ansatz wurde zuletzt anhand eines auffälligen Beispiels bekannt: Als die Transportkapazitäten für den Export nach Europa nicht ausreichten, ließ einer dieser Hersteller kurzerhand selbst eines der weltweit größten Autotransportschiffe bauen. Branchenschätzungen zufolge entfallen 70 bis 80 Prozent der Wertschöpfung an einem deutschen Fahrzeug heute auf Zulieferer, nicht auf das Werk des Herstellers selbst. Dieses dezentrale Modell weist eigene Vorzüge auf: Der Wettbewerb zwischen den Zulieferern sorgt für eine Fokussierung auf Innovationskraft und Kosten, und es ermöglicht eine flexiblere Reaktion auf schwankende Stückzahlen oder sich ändernde Modellspezifikationen als ein System mit starker vertikaler Integration. Die Schattenseite: Eine über zahlreiche Zulieferer generierte Qualität erfordert aktives Management – sie ergibt sich nicht mehr automatisch in den eigenen Räumlichkeiten. Die Zahlen verdeutlichen, was auf dem Spiel steht: Im Jahr 2024 registrierte das Kraftfahrt-Bundesamt 2,84 Millionen zurückgerufene Fahrzeuge, was einem Anstieg von 48 Prozent im Vergleich zum Vorjahr entspricht. Ein essenzielles Instrument, um Qualität über Werksgrenzen hinweg zu managen, ist seit vielen Jahrzehnten der 8D-Report: Zulieferer sind verpflichtet, Reklamationen in diesem Format zu bearbeiten, einschließlich der Fehlerbeschreibung, der Ursachenanalyse und der nachweislich effektiven Abstellmaßnahme. Genau an diesem Punkt setzt QualityPilot der Mannheimer SUSI&James GmbH an – ein KI-gestütztes System, das eingereichte 8D-Reports automatisiert prüft. Vom Verwaltungsakt zum Steuerungsinstrument In der Praxis wird der 8D-Report oft als abschließender Verwaltungsakt verwendet: Die Analyse, der Kundenschutz und die technische Ursachenklärung laufen parallel und sind wenig strukturiert. Dokumentiert wird oft erst im Nachhinein – nicht selten sitzt ein Qualitätsverantwortlicher allein und verfasst den Bericht rückblickend zusammen. Aus Sicht von SUSI&James sollte der 8D-Report von Beginn an begleitend geführt werden: Jede der acht Disziplinen wird bearbeitet und sofort mit dem Kunden geteilt, damit dieser den Fortschritt kontinuierlich nachvollziehen und selbst Maßnahmen zur Risikominderung ergreifen kann. Nur so wird das 8D zu einem echten Steuerungsinstrument und nicht nur zu einer nachträglichen Dokumentation. Weiterlesen https://t1p.de/5p1kn Bilder: © SUSI&James GmbH Thomas Ohde Director Operations Ansprechpartner für technische Fragen zum 8D QualityPilot thomas.ohde@susiandjames.com Telefon +49 162 751 84 89 Christian Düsi Projektleiter koordiniert Pilotprojekte und Kundengespräche christian.duesi@susiandjames.com Telefon +49 171 629 99 80 Medina Hodzic Referentin für digitale Kommunikation Ansprechpartnerin rund um das Thema Marketing, Autorin des Beitrags medina.hodzic@susiandjames.com Telefon +49 173 796 86 54
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Böllhoff Group Böllhoff is a competence leader in 360° Joining Technology. As a family-run company, we have stood for long-term success through innovative capacity and local presence since 1877. We seek to understand the needs of our customers and deliver solutions to fit their requirements. We focus on innovative, sustainable and economical solutions along our customers’ entire value chain. Over 3,300 employees are shaping the future of joining technology – both at our Image: © Böllhoff headquarters in Bielefeld, Germany, and at our subsidiaries around the world. Our broad range extends from standard screws to special fasteners and assembly systems. A wide range of services related to joining technology complete our portfolio, from testing of fasteners in our accredited laboratory to application-related advice and cost-effective delivery solutions. Böllhoff is a fourth-generation family-run business. It is currently run by Wilhelm A. Böllhoff and Michael W. Böllhoff (managing partners), as well as Dr Cathrin WeschPotente, Dr Jens Bunte and Thomas Pixa. info@boellhoff.com � www.boellhoff.com � Annette Löwen Team lead Marketing Germany PFM Böllhoff Verbindungstechnik GmbH Archimedesstr. 1–4 D-33649 Bielefeld Phone +49 521 4482 451 Advertisement Böllhoff www.boellhoff.com � 22
Phone +49 521 44 82-1387 fat@boellhoff.com www.boellhoff.com RIVKLE® Automation E Revolutionary electric RIVKLE® setting system for blind rivet nuts and studs. Benefit from the following advantages, among others: Elektronic management of the setting parameters High speed and accuracy, with full control and optimum repeatability Hole finding support Hole misalignment compensation and automated orientation of fastener Elektric power Simplified maintenance and reduced environmental footprint, providing better availability rate Do you have a current project? Here you will find the ideal solution for demanding, high-volume applications. We look forward to the conversation.
24 SUSI&James GmbH is a leading provider of digital employees, specialised in processes within the branches automotive, industry and trade. With the help of our patented, “hybrid” AI, we provide a wide range of cross-industry support for several kinds of processes since 2015. We bundle the latest technologies in our technology platform: with this, we combine machine learning processes, language processing and methods for process automation in one product. This is how our digital employees are created. They can partially or completely take over manual work in companies. Our digital employee SUSI can understand speech, write and read, operate programmes and solve tasks independently. SUSI can be trained quickly and intuitively. Through the quick integration, SUSI can provide shortterm and sustainable relief for organisations, accelerate processes, reduce costs and increase efficiency. SUSI&James GmbH est le fournisseur leader de collaborateurs numériques, spécialisé dans les processus de la construction automobile, de l'industrie et du commerce. À l'aide de notre intelligence artificielle �hybride� patentée, nous apportons notre soutien à différents processus d'optimisation et/ou de communication dans tous les secteurs, depuis 2015. Nous réunissons les technologies les plus avancées dans notre plateforme technologique : celle-ci nous permet de réunir en un seul produit des méthodes d'apprentissage automatique, de traitement du langage et d'automatisation des processus. C'est ainsi que naissent les collaborateurs numériques, qui peuvent remplacer partiellement ou totalement les activités manuelles dans les entreprises. Notre collaborateur numérique SUSI peut comprendre la parole, écrire et lire, utiliser des programmes et résoudre des tâches de manière autonome. SUSI peut être entraînée rapidement et intuitivement. Grâce à l'intégration rapide, SUSI peut soulager les organisations à court terme et de manière durable, accélérer les processus, réduire les coûts et augmenter l'efficacité. Die SUSI&James GmbH ist führender Anbieter für digitale KI-Mitarbeiter, spezialisiert auf Prozesse im Automobilbau, Industrie und Handel. Mithilfe unserer patentierten, „hybriden“ KI unterstützen wir seit 2015 branchenübergreifend bei unterschiedlichsten Optimierungs- oder/und Kommunikationsprozessen. Wir bündeln die neuesten Technologien in unserer Technologieplattform: Mit dieser vereinen wir Maschine Learning-Verfahren, Sprachverarbeitung und Methoden zur Prozessautomatisierung in einem Produkt. So entstehen die digitalen Mitarbeiter, die in Unternehmen manuelle Arbeiten partiell oder vollständig übernehmen können. Unsere digitale Mitarbeiterin SUSI kann sprechen, verstehen, schreiben und lesen, Programme bedienen und Aufgaben selbstständig lösen. SUSI ist schnell und intuitiv trainierbar. Durch die schnelle Integration kann SUSI kurzfristig und nachhaltig Organisationen entlasten, Prozesse beschleunigen, Kosten senken und Effizienz steigern. SUSI&James GmbH Turley-Straße 8 68167 Mannheim Germany Phone +49 621 483 493 42 mail@susiandjames.com www.susiandjames.com Advertisement
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