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 reality

In this phase, our research and development team offers effective support in helping to make your projects a reality. Choose from our diverse fields of expertise in the development areas of PCB Design, Electronics, Mechanical Systems, Quality, Software and Project Management. We focus on personalized consulting and support during the product development concept phase, and we are there to assist you in drawing up the technical specifications and evaluating solutions. Along with that, we also provide support in the design, prototyping, sample production, integration, testing, and product certification phases. Even after the development phase has been completed, we continue to perform product maintenance, upgrades, redesigns, and more throughout the lifecycle of the product.

Production-related development

As your development partner, we carry out sub-tasks or take on full responsibility for the project, drawing on uniform, stable processes from the idea to serial production. Early on in the project, we take into account what will be produced and/or tested at a future time. This is how we ensure high product quality right from the start. We also advise our customers in the selection of components and materials, with a constant eye on delivering the best value for your money. We exploit synergies worldwide created by our international networks of excellence. Our strength lies in our ability to link different areas of expertise in and around complex mechatronic systems in order to develop groundbreaking concepts and innovative ideas and act in a strategic manner.

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
    • Optoelectronics
    • Embedded systems
    • High frequency
  • System design
  • Simulations
    • Electronics (Plecs / LTspice®)
    • Induction and HF technology (Comsol)
    • 2D / HF technology (AWR microwave)
    • 3D / HF technology (CST Studio)
  • Tools
    • Mentor Graphics
    • Altium
    • EPLAN

Project Management

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


  • 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