Research & Development

Your professional partner from day one – we put your projects on a solid foundation. The groundwork for a successful, cost-effective product is laid as far back as the development phase. Work with us to develop pioneering concepts, forward-looking ideas and strategic activities.

Transforming ideas into serial maturity

Our Research & Development Division already supports you from the idea, all along the entire product development process and all the way to serial maturity in the realization of your projects. We rely on individual consultation and support. In doing so we take over all development services for you, from requirements engineering, including standard research, through concept development, detail design, sample creation and product qualification right up to organization of global product accreditations. Equally important as the fulfillment of technical requirements is the achievement of stated goals for manufacturing costs for the product. We guarantee this through constant tracking and assessment of the applicable influencing factors. Even after completion of the development phase, we stay as your partner and take care of the complete life cycle of the product in topics like product maintenance and optimization.

Mechatronic systems

One of our strengths is the intertwining of the most differing hardware, software and mechanics into complex mechatronic systems to develop pioneering concepts and foresighted ideas and act strategically. If you have system competence in your house, then you can select from our manifold fields of expertise in the development fields of PCB design, electronics, control cabinet design, mechanics, quality, software and project management. Whether complete system development and support or individual services, we always offer the right solution for your needs.

PCB Design

Design of PCBs optimized for series production – from single sided PCBs to HDI multilayer boards technology

  • Rigid, flex and rigid-flex PCBs incl. Microvia-Design
  • Signal- / power integrity / High Speed / EMC
  • High Current Design
  • High Voltage Design
  • Review and adaptation of third-party designs with a view to optimized production at Zollner, taking into account the entire design chain
  • Design for Excellence (DfM, DfT, DfR, …) / Design Rule Checks
    (Bare Board-, Component-, Hazard-, Tombstone-, Test Point-, Creepage-, Selective Wave-, AOI Coverage-, Net list-Analyses, …)
  • Simulation
    • Thermal (Joule Heating)
    • Signal- / Power Integrity
  • EDA Design Tools
    • Altium Designer
    • Cadence Allegro
    • Easylogix PCB-Investigator
    • Siemens (Mentor Graphics) XpeditionSiemens (Mentor Graphics) Xpedition


  • CAD development of individual parts, devices and complete mechatronic systems
  • Materials: Metal, plastic, composites
  • DFx
  • Simulations
    • Static structure simulation
    • Kinematics and kinetics
    • CFD (heat conduction, convection, radiation, flow)
  • Tools: Ansys Mechanical, CREO Simulate, SolidWorks flow simulation
  • Software-supported tolerance analysis
  • Connection technologies
  • CAD tools
    • SolidWorks
    • Creo Parametric
    • Catia V5
    • Solid Edge
  • CAD data repair
    • 3D Evolution
  • Rapid Prototyping
    • Laser sintering (polyamide)


  • Development of inductive components, circuits and control applications for complete systems in
    • Power electronics
    • Embedded systems
    • High frequency
  • Simulations
    • Electronics (Plecs/LTspice®)
    • Induction and HF technology (Comsol)
    • 2D/HF technology (AWR microwave)
    • 3D/HF technology (CST Studio)
  • Tools
    • Mentor Graphics
    • Altium


  • Iterative development of real-time embedded software in "C" with system concept
    • Requirements engineering
    • (UML) architecture and detailed design
    • Implementation and unit test
    • Transition to system test
    • IEC 61508, IEC 62304, ISO 26262, IEC 60335
  • Platforms
    • ARM Cortex M0, M0+, M3, M33, M4, M7
    • Cortex-A7 and A53
    • Infineon Aurix
    • Various Bluetooth & BLE controllers
    • Baremetal for best performance with minimal computing power
    • FreeRTOS
    • Embedded Linux (YOCTO)
  • Tools
    • Sparx Enterprise Architect
    • Doxygen
    • IAR Embedded Workbench
    • Keil µVision
    • Visual Studio Code
    • Scitools Understand
    • VectorCAST


  • Quality planning
    • Risk assessment
    • Requirements management
    • FMEA / FMEDA / FTA
    • Functional safety
  • Product qualification
    • System test
    • Environmental simulation
    • Lifetime test / MTBF calculation
    • Mechanical type testing
  • Function test
    • Electrical tests
    • Hardware in the Loop (HiL)
  • Internal laboratories
    • EMC laboratory (180 m²)
    • Safety laboratory (30 m²)
    • Environmental test center (1050 m²)
    • Optics laboratory (20 m²)
    • Robot system test bench (100 m²)
  • International certification and approval management
    • Europe (e.g.: CE, RED, MDR, IVD)
    • North America (e.g.: UL, CSA, FCC/IC, FDA)
    • Korea, China, Japan (e.g.: KCC, CCC, PSE)
    • etc.
  • Tools
    • Siemens Polarion
    • National Instruments LabView / TestStand
    • MicroNova EXAM

Project Management

  • Central contact person for
    • Customers
    • Suppliers
    • R&D departments
    • Production
    • Management
  • Services
    • Project planning
    • Project organization
    • Project communications
    • Project monitoring

Production-related development

We have standardized, stable processes from the idea to serial maturity. With our Simultaneous Engineering approach (synchronous development of product and production processes), we take into consideration what must later be procured, produced and tested and how. Thus we secure a high level of product quality on the one hand and efficient processes all along the supply chain on the other.