Hamburg Aviation Cluster a Winner

The Aviation Cluster Hamburg Metropolitan Region is Germany’s Leading Edge Cluster. With its integrated strategy for “A new kind of aviation”, the civil aviation industry in the Hamburg Metropolitan Region emerged as one of five winners amongst 38 clusters from various industries that participated in the Leading Edge Cluster Competition organised by the Federal Ministry of Education and Research in September 2008. Pursuing the principle of strengthening excellence, the aviation cluster will receive federal funds of 40 million euros over the next five years; this funding must be fully counter-financed by the industry.

Covering the entire life cycle of civil aircraft, the integrated strategy “A new kind of aviation” aims at making aviation more economical, more ecological, more comfortable, more reliable and more flexible.

The holistic approach thus reflects the core competences of Hamburg as the place for aviation. The industry’s competence is based on four pillars: aircraft and aircraft systems, cabin and cabin systems, air transport systems, and aviation services.

The new cluster strategy incorporates three flagship projects: “Cabin Technology and Innovative Fuel Cell Applications”, “Extended Maintenance, Repair and Overhaul (MRO) for Future Aircraft Generations” and “Airport 2030“. These outstanding projects are headed by Airbus, Lufthansa Technik, and the German Aerospace Centre (DLR) in cooperation with Hamburg Airport. These major players also involve a substantial number of small and medium-sized companies, universities, and research institutes with their efforts. The overall strategy calls for the implementation of about a dozen projects and activities in research & technology and cluster management.

The “Cabin Technology and Innovative Fuel Cell Applications” project focuses on the use of lightweight materials and hydrogen-based fuel cells to effect a significant reduction in emissions and resource consumption. The development of fuel cell technology is an important factor in making future aircraft generations more environmentally friendly and efficient. The “Extended Maintenance, Repair and Overhaul (MRO) for Future Aircraft Generations” project aims at extending existing competencies to future aircraft generations. Innovative materials research, diagnostics, and information, automation and process technologies are aimed at ensuring optimal support throughout the new jets’ life cycles (maintenance, repair, overhaul, modification). Emphasis is placed upon the use of new materials and the adaptation of conventional maintenance methods to these new materials. Using the example of Hamburg Airport, the flagship project “Airport 2030” concentrates on developing economically sustainable concepts and solutions to address the increase in air traffic. This project is a great opportunity for Hamburg Airport and the German Aerospace Centre to advance new technologies in an area with great potential in Hamburg, namely aviation processes and aviation process management. Likewise, aircraft design in Hamburg is receiving a substantial boost. This is resulting in new product lines with excellent market potential, especially for SMEs.

Alongside the three flagship projects, there are currently nine other research projects with numerous partners from within the network: AkuKon – acoustic concepts for aviation of the future (managed by Lufthansa Technik), the development and manufacture of a CFRP seat (Carbon Fibre Reinforced Plastic) by Innovint, aircraft seat rails from Bishop GmbH, Hybrid – empowering hybrid teams for decision-making at the German Aerospace Centre (DLR), LiKab – light sensitivity and cabin climate, also at DLR, Opti-Struct – optimised titanium-CFRP interface structures (joint project of FormTech, Hein&Oetting, GKSS Research Centre in Geesthacht), SEED – Simultaneous Production Engineering Education (managed by Airbus), SMART – Smart Aircraft Ramp-up Technologies for Design, Assembly and Logistics (managed by Airbus) and Environmentally Friendly Services and Products in Hamburg aviation, provided by Hamburg Airport.

Two infrastructure projects, strongly reflecting the cluster idea, further enhance the organisation of the cluster: the Hamburg Centre of Aviation Training and the Center of Applied Aeronautical Research (ZAL).

At the Hamburg Centre of Aviation Training (HCAT), the aviation industry, universities and vocational schools have bundled demand-oriented qualification in a public private partnership. With school education, corporate training, and university studies under one roof, the new facility is unique in Europe. The principal participants are Hamburg’s Ministry of Education and Professional Training (BSB), the Ministry of Economic and Labour Affairs (BWA), the Ministry of Science and Research (BWF), the State Vocational School for Manufacturing and Aircraft Engineering (G15) and the University of Applied Sciences (HAW Hamburg); Lufthansa Technical Training and Airbus are corporate partners. Their joint aim is to obtain qualified personnel for the aviation industry with the help of further education, work adjustment training, and academic tuition. Key aspects are avionics/electronics, cabin/cabin systems, and modern production methods/new materials.

The Center of Applied Aeronautical Research (ZAL) forms the nucleus of the cluster’s joint research and technology activities. It brings its partners – companies of the aviation in-dustry and universities – closer together, creates synergies through the shared use of test platforms, and makes the Hamburg Metropolitan Region attractive to new partners. The management is located at Hamburg Airport, the test rigs will be set up in a new building at Rüsch peninsula and on the grounds of Lufthansa Technik. In addition, the Finkenwerder site will receive a new application-oriented facility with the establishment of a fuel cell lab. There, the applications of fuel cell technology on-board aircraft as an alternative energy source and the reduction of CO2 emissions by aircraft will be explored. In cooperation with aviation com-panies such as Airbus and Lufthansa Technik, universities, research facilities, and industry associations, the Free and Hanseatic City of Hamburg is investing approximately 10 million euros into ZAL’s formation. A further 3.7 million euros will spent on test rigs for the aviation related fuel-cell research.