Fraunhofer Institute for Production Technology IPTResearch project "HEPAD"
Overcoming the challenges of traditional transport logistics with drones
The partners in the HEPAD project are addressing the challenges of overburdened short-distance logistics in North Rhine-Westphalia: A particularly large number of deliveries here are under 50 kilometers, making neither rail nor road a viable option. This is because both conventional modes of transport are designed primarily for long distances, large volumes, and complex infrastructure. Drone transport provides a solution here, but existing systems are unable to carry heavy loads.
Sustainable and high-performance: heavy-lift drones
Heavy-lift drones fill this gap: They can take off from almost anywhere, require no additional infrastructure, operate emission-free, and move goods where roads are congested or other modes of transportation cannot reach. They are ideal for short, heavy, and time-sensitive shipments that are currently mostly handled by trucks.
In the HEPAD project, the project consortium is developing a high-performance logistics drone that carries a significantly greater payload than existing systems and provides a new, electric transport option. It relieves traffic congestion, reduces emissions, and enables flexible, fast freight transport.
Reducing dead weight, increasing payload
In the HEPAD project, scientists are combining newly developed high-power batteries, ultralight propulsion components, and an optimized lightweight structure into an integrated system. The system monitors each cell individually, allowing it to determine the state of charge and aging more accurately while increasing operational safety.. The drone utilizes an aerodynamically optimized structure that reduces weight and increases efficiency. Thanks to this consistent system integration, the HEPAD drone achieves an exceptionally high payload-to-weight ratio.
Digital connectivity and demonstrator operations
To this end, the project team is developing an IoT architecture that continuously collects and analyzes operational and status data. The system supports fleet management, mission planning, and predictive maintenance. A demonstrator showcases the drone’s performance in real-world operations and can be compared with existing technologies. The results provide a solid [BC1] basis for optimizing the drone in terms of range, efficiency, safety, and environmental impact.
Benefits for logistics, cities, and industry
The HEPAD project delivers clear added value to companies, cities, and manufacturers: Logistics service providers benefit from a new, high-performance transport drone for short, heavy-load, and time-critical missions; cities benefit from reduced traffic and lower emissions, while manufacturers gain a proven technology toolkit for high-power energy systems and lightweight construction solutions. This creates a scalable foundation for modern, connected, and sustainable air logistics.
Project Consortium
- MANUGY GmbH, Cologne
- Exabotix GmbH, Bad Lauterberg im Harz
- Fraunhofer Institute for Production Technology IPT, Aachen
- University of Münster, Münster
- RWTH Aachen University, Aachen
- PEM Motion GmbH, Aachen
- University of Twente, Enschede (Netherlands)
Project coordination: Fraunhofer Research Institution for Battery Cell Production FFB
Funding
The HEPAD research project is funded by the European Union and the state of North Rhine-Westphalia as part of the ERDF/JTF program NeueWege.IN.NRW.
Funding code: 20801734
Project sponsor: PTJ Projektträger Jülich