In the category "Automotive and Road Transportation – Process," the team from Chemnitz University of Technology, together with Gerlinger Industries and other industry and research partners, prevailed against global competition. The award, considered the "Oscar of the composite materials industry," was presented on January 12, 2026, during a festive ceremony in Paris. A total of 154 applications were submitted, from which 33 finalists were selected. One winner was chosen in each of eleven categories.
Paradigm shift in electric mobility
The award-winning "GroKuBat" project (large-scale production-ready plastic battery housing) provides an answer to one of the most pressing questions facing the automotive industry: How can heavy metal components in electric vehicles be replaced safely, quickly, and more sustainably? "With this success, we are impressively demonstrating that fiber-reinforced thermoplastics are ready for large-scale production," says Prof. Dr. Wolfgang Nendel, deputy head of the Chair of Lightweight Structures and Polymer Processing at Chemnitz University of Technology. "Our goal was not only to functionally replace a metallic reference concept. We wanted to show that, through intelligent process control and material combinations, we can be both ecologically and economically superior without compromising on safety. This award confirms in particular the innovative strength of Chemnitz as a research location."
Technological breakthrough: less than two minutes per component
The core of the innovation is a highly automated manufacturing process based on extrusion technology. By combining commercially available long and continuous fiber-reinforced thermoplastics, the researchers were able to achieve cycle times of well under two minutes per component. This proved that plastic housings can be manufactured competitively in large quantities compared to established solutions made of aluminum or steel.
Convincing facts: Lighter, greener, safer
The international jury of experts particularly praised the holistic improvements that the project has achieved. In addition to demonstrating the large-scale production capability of the large-format traction battery housings, this also applies to weight savings: the battery housing is around 15 percent lighter than the aluminum reference, which directly increases the range of electric vehicles. Sustainability is also exemplary:CO2 emissions are reduced by around 25 percent over the entire life cycle – thanks to lower mass, more efficient production, and optimized recyclability. The innovative battery housing also impresses in terms of safety: Extensive testing, including simulations and physical Euro NCAP pole impact tests, proves that the plastic housing fully meets the stringent requirements for structural integrity.
Presentation in March at the world's leading trade fair, JEC World 2026
While the award has already been accepted in Paris, the grand public presentation of the winning component is still to come. The Chair of Lightweight Structures and Polymer Processing will present the battery housing at the world's leading trade fair, JEC World 2026. This will also take place in Paris from March 10 to 12, 2026. Visitors can view the exhibit at the joint stand of the Saxony Economic Development Corporation (Hall 5, Stand D97) and talk to the scientists about the manufacturing process.
Background: Joint project "GroKuBat"
In purely battery-powered passenger cars, the traction battery located in the vehicle underbody has become the established design. Despite the favorable center of gravity achieved as a result, there is still a demand for lighter batteries, as high weight continues to have a negative impact on range and driving dynamics. The increased use of lightweight materials for battery housings, such as glass fiber-reinforced thermoplastics, is a promising option for counteracting the high weight. As part of the joint project "GroKuBat" (large-scale production-ready plastic battery housing), such a housing was developed and constructed for large-scale production, taking into account the entire value chain. The research project was supported by the Federal Ministry of Economics as part of the "New Vehicle and System Technologies" funding guideline from 2022 to 2024. Its success is based on close cooperation between research and industry. In addition to Chemnitz University of Technology (Chair of Lightweight Structures and Plastic Processing), the consortium included partners Mahle Filtersysteme GmbH (project coordinator), Formenbau GF GmbH, In2p GmbH, Gerlinger Industries GmbH, Wickert Maschinenbau GmbH, and the Fraunhofer Institute for Chemical Technology (ICT).
