The project enables ZF to reduce conversion costs, improve inventory, performance and quality, and make their workforce more efficient. As all companies are a member of the Open Manufacturing Platform, other customers in the automotive industry will also benefit from ZF’s improvements gained in Diepholz

Transforming manufacturing requires a seamless integration of both information and operations technology. PwC Germany, part of one of the world’s leading professional service firm networks, Microsoft and ZF, as two of the world’s leading technology companies, combine their strengths and experience to translate complex technical information into valuable business insights. The ZF Diepholz plant in northern Germany was selected for a pilot project where ZF and PwC Germany will transform processes and workflows using Microsoft Azure to build the future Digital Manufacturing Platform (DMP) of ZF.

“The world is changing, and so is manufacturing,” says Gabriel González-Alonso, Head of ZF Corporate Production Management. “In these very turbulent times, it was especially important to us that we implement new digital solutions that enable our manufacturing to achieve higher flexibility and efficiency.” This is nothing less than a paradigm shift for ZF. In the past, the software was introduced into each plant one by one and installed on discrete servers. This has evolved into creating a platform in the cloud, connecting ZF’s plants to said platform and rolling out the functionalities to the plant via Microsoft Azure. This horizontal, cross-plant integration with easy scalability makes ZF independent of its local infrastructure.

“To further digitise the ZF Diepholz plant, we will implement a transformation programme with several additional use cases, all of which will be integrated into an end-to-end Smart Factory Transformation for ZF,” explains Michael Bruns, Partner Digital Operations at PwC Germany. Selected cases will aim at creating transparency of production performance from the plant as a whole all the way down to machine level. Others will focus on the traceability of production flows, analysis and prediction of production, and quality outcomes. The third set of used cases aims at enhancing maintenance operations through machine monitoring and fault prediction.

To master these tasks, ZF and PwC Germany will use Microsoft AI to improve planning efficiencies and effectiveness, improve maintenance, repair, and operations (MRO) inventory and present new insights to improve production performance.

Microsoft, which provides the software solutions for PwC Germany’s approach, sees this project as relevant for the digital strategy for all automotive suppliers like ZF. “Our aim is to make this initiative not only a best practice for success at ZF but also an industry-wide inspiration to other automotive customers endeavouring on their own digitalisation projects. We see strong interest across the manufacturing sector globally to leverage digital technologies to drive quality as well as process optimisation, and we’re excited for this project to serve as a true benchmark,” says Marianne Janik, Area Vice President, Microsoft Germany.

The partners will come together to bring fully-networked plants to the next level. Smart factories not only work quickly and reliably, but they also offer a high degree of adaptability for rapid design changes. This leads to more engaged employees, increased business velocity, and stronger growth margins.

Not only will other ZF plants benefit from the insights gained from digitising the Diepholz plant and the capabilities of the DMP, but other organisations may benefit as well. (MT)

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Researchers at Chalmers University of Technology, in collaboration with industry partners, have published a study in Nature Communications demonstrating that reconfigurable battery pack architectures can extend electric vehicle battery operational life by more than 20 percent under specific conditions.

In conventional electric vehicle battery packs, cells are wired in a fixed series configuration, meaning the weakest cell dictates the overall capacity, performance and lifespan of the entire pack. The architecture evaluated by the Chalmers engineering team uses integrated electronic switches and a centralised battery management system to monitor individual cells or cell groups. When a cell experiences accelerated degradation or reduced capacity, the system bypasses the degraded unit while electric current continues to flow through the remaining functional cells.

Albert Skegro, a PhD student at the Department of Electrical Engineering at Chalmers University of Technology, said, "They must all move at the pace of the slowest person and stop when that person stops, regardless of how much energy the others have left. With the architecture we have modelled, the battery can instead bypass the cell that is causing problems and continue using the remaining cells."

Changfu Zou, Professor at the Department of Electrical Engineering at Chalmers, said, "Reconfiguration is not an on-or-off choice. It is a spectrum. Where a manufacturer chooses to position itself on that spectrum determines how much of the potential benefit can be realised."

In a representative modelling scenario featuring an 80 kWh battery pack driven 12,000 kilometres annually over an 18.8-year vehicle lifespan, the reconfigurable system deferred battery replacement by approximately 14 months. The researchers noted that the technology yields the highest performance gains in high-voltage vehicles, including 400-volt and 800-volt electric passenger cars and commercial trucks, where higher cell counts in series increase the statistical probability of individual cell variance.

A techno-economic analysis included in the study determined that implementing cell-level switching hardware increases initial pack production costs by approximately nine per cent based on prototype-scale volumes of 1,000 units. The researchers identified an economic break-even threshold at a 12 percent cost increase, noting that volume manufacturing would lower component costs and increase financial viability for fleet operators and private owners. While prototype applications such as Volvo Cars' SmartCell concept and experimental road vehicles exist, mass-production vehicles using reconfigurable battery packs are yet to enter the commercial market.

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Jakson Green Vehicles has selected Dassault Systèmes’ cloud-based 3DEXPERIENCE platform to manage the design and development of its electric vehicles.

The implementation establishes a collaborative engineering framework to maintain digital continuity across the product development lifecycle. By connecting internal teams and external suppliers, the platform automates workflows, standardises component libraries and manages engineering change requests during early-stage product design. Virtual twin capabilities allow the vehicle manufacturer to conduct virtual validation testing to resolve structural and systems design issues prior to physical manufacturing.

Deepak Thakur, CEO, Jakson Green Vehicles, said, "Using Dassault Systèmes’ 3DEXPERIENCE Platform enables us to apply a collaborative approach and re-engineer our product lifecycle from the ground up. Through this transition from legacy environments to a unified digital thread, it enables strong R&D to achieve twin objectives; accelerated time-to-market and mitigated development costs. This partnership is helping us to transform the early-stage innovation and product design processes."

Deepak NG, Managing Director – India, Dassault Systèmes, said, "As India continues its dynamic growth trajectory, virtual twin technology serves as a powerful catalyst for sustainable innovation, empowering industries to rethink how they design, produce and operate."

The software adoption forms part of Jakson Green Vehicles' plan to build urban zero-emission mobility vehicles and infrastructure across India.

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UK-headquartered energy technology company Gelion has entered into a material transfer agreement with a top 15 global automotive original equipment manufacturer to assess its NES cathode platform for future electric vehicle battery applications.

Under the terms of the agreement, Gelion will supply its sulfur-based cathode active material, coated cathodes and liquid electrolyte to the automotive partner. The manufacturer will evaluate the platform in both liquid and solid electrolyte cell configurations, testing compatibility across lithium metal and graphitic anode pathways targeting luxury and mass-market vehicle applications. The technology is designed to serve as a drop-in cathode material capable of integration into existing battery manufacturing lines without re-tooling.

Matt Wood, Chief Executive Officer, Gelion, said, "Our priority markets are commercial & defence drones, EVs and devices. We are honoured to be working with these major global automotive OEMs, and today’s announcement marks further progress towards the adoption of our technology and the generation of commercial revenues via funded programmes and eventually license and royalty revenue in the global EV market, alongside some of the industry’s leading companies."

"The growing engagement from global EV manufacturers reinforces the potential and attractiveness of our NES™ technology. This momentum is also mirrored in our agreements and partnerships across drones and devices, while our work with Tier 1 materials suppliers is advancing the scale-up of our unique, patented battery materials," Wood added.

The agreement expands Gelion’s ongoing industry testing programs with automotive manufacturers, extending the assessment of its sulfur-based cathode platform across liquid and solid battery systems.

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Honda R&D, a subsidiary of Honda Motor Co., has developed underlying technology for a magnetic coupling wireless power transfer road system in partnership with Taisei Corporation and Taisei Rotec Corporation.

The system enables wireless in-motion charging for electric vehicles, including passenger cars and heavy commercial fleets. The partners plan to initiate demonstration testing on public roads starting in FY2027.

The technology integrates high-power-density receiver and transmitter units from Honda with a high-response direct current power supply system from Taisei and road-embedding construction techniques from Taisei Rotec. By supplying power to electric vehicles while in motion, dynamic wireless power transfer reduces the need for stationary charging infrastructure. The initial commercial focus targets logistics and transport operations, where continuous operation offers economic benefits.

The ground assembly embedded in the roadway combines the inverter and coil into a single unit designed to connect via direct current distribution. This design reduces component counts, simplifies wiring and supports installation into existing road surfaces through standard milling methods. The road pavement structures are engineered to withstand continuous traffic loads from vehicles weighing up to 20 tonnes (20,000kg).

Testing conducted at Taisei Group’s T-FIELD facility in Satte verified system stability and structural durability. Starting in late 2026, the companies will build a test roadway at T-FIELD Tamura to evaluate long-term durability under one million wheel-load cycles, measure power transfer efficiency at outputs up to 150 kW and analyse electromagnetic shielding.

The partnership will also join the Tateyama Expressway demonstration project managed by East Nippon Expressway Company starting in 2027.

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