San Diego, CA – In a world grappling with the urgency of the climate crisis and a surging demand for mobility, a group of engineering students from Germany is determined to revolutionize how we move. At Autodesk University in San Diego last month, Johannes Anton Mootz, the Lead Structure and Packaging engineer for mu-zero HYPERLOOP, shared a bold vision: a transportation future where high-speed, low-emission travel could seamlessly connect cities and reduce the carbon footprint of short-distance flights. Mootz, a PhD candidate at Karlsruhe Institute of Technology (KIT) and former lead structural engineer for the mu-zero Hyperloop team, provided a captivating look at how his team is leveraging cutting-edge technology and an innovative collaborative approach to make that vision a reality.

A Vision for Sustainable Travel

Opening his presentation with a call to action, Mootz emphasized that the climate crisis demands an urgent overhaul of our current mobility systems. The mu-zero HYPERLOOP project, now in its fourth year, is rooted in the idea that mobility can and must evolve toward sustainability. “One solution to the climate crisis could be the Hyperloop,” Mootz explained, describing the concept as a high-speed, near-supersonic transportation mode operating in a vacuum-sealed tube to eliminate friction and drastically reduce energy consumption. With the mu-zero HYPERLOOP prototype, his team has shown that short-haul transportation could be transformed by this technology, minimizing emissions while maintaining, or even exceeding, the speed of air travel.

The Hyperloop’s appeal lies in its efficiency and speed. By operating in a low-pressure environment, Hyperloop pods encounter almost no drag, allowing them to travel at speeds three times faster than traditional trains, with significantly lower energy requirements. This radical approach, Mootz highlighted, has the potential to make intercity travel as fast and convenient as short-haul flights, while consuming only a fraction of the energy and producing zero direct emissions. The mu-zero Hyperloop team, with more than 50 members across engineering disciplines, is working to bring this vision to life one prototype at a time.

The Team Behind the Pod

Mootz’s presentation underscored the essential role of teamwork and collaboration. Mu-zero HYPERLOOP is a student-led initiative comprising over 50 members from four German universities, including KIT, all of whom share a mission to develop a fully functional Hyperloop pod. Representing a blend of diverse backgrounds, the team includes students from fields like mechanical engineering, software, electronics, finance, and marketing. Their work is divided into two main sectors: technology and operations. On the technology side, there are specialized teams focused on key aspects of the pod, such as structural design, propulsion, aerodynamics, guidance, software, and electronics. The operations teams handle marketing, finance, event management, and sponsorship, keeping the business aspect of the project running smoothly.

This cross-functional collaboration allows the team to tackle the immense technical challenges of the Hyperloop project while managing complex logistics, budgets, and outreach efforts. “Each team member brings a unique skill set to the table,” said Mootz. “Our organization is structured to mirror a tech startup, giving students real-world experience in both engineering and business.”

The Engineering Journey: From Concept to Prototype

The journey to building a Hyperloop pod is a rigorous, year-long cycle involving distinct phases: concept, design, manufacturing, and assembly. Each fall, the team enters the concept phase, where they set their goals for the year. “We start by defining our objectives for the season, which includes integrating new technology and pushing our pod’s performance to new limits,” Mootz explained. This phase includes brainstorming sessions and team workshops where initial sketches and ideas are evaluated for feasibility.

By winter, the team transitions to the design phase, using Autodesk Fusion as their primary design and engineering platform. Mootz elaborated on the immense complexity of working with over 25,000 individual components, all designed, optimized, and simulated within Fusion. Generative design tools and finite element analysis (FEA) simulations help ensure that the frame and other components can withstand the demands of high-speed travel. “Fusion’s all-in-one design capabilities allow us to simulate and iterate rapidly, which is crucial when working with such a large team and limited time,” Mootz noted.

Spring marks the beginning of manufacturing, where the team collaborates with local industry partners to produce the large, high-precision components required for the pod. This phase is particularly challenging, as design flaws often reveal themselves during manufacturing, necessitating quick adjustments to ensure the parts fit seamlessly. Mootz emphasized the importance of adaptability and resilience. “Manufacturing is where our theoretical designs are tested in the real world. It’s challenging, but it’s also where our project truly comes to life.”

The final phase, assembly, takes place in the summer, when the team brings together thousands of parts to construct the pod. Rigorous testing is conducted to ensure safety, reliability, and performance, all in preparation for the annual European Hyperloop Week (EHW) competition. Held in Switzerland, EHW brings together more than 25 teams from around the world, each showcasing their prototype and competing for awards.

Achievements and Recognition

The mu-zero HYPERLOOP team’s work has not gone unnoticed. In the recent EHW, their prototype took second place in the Complete Pod category, a newly established accolade that recognizes the most well-rounded and functional Hyperloop designs. “It’s a tremendous honor,” Mootz said. “We’re proud to be recognized among the best in the world, and we’re already looking forward to pushing for first place next year.”

But for the team, the Hyperloop project is about more than winning awards. Mootz and his colleagues view their work as a hands-on learning experience and an opportunity to apply classroom knowledge to a real-world project. “This project allows us to get our hands dirty and develop skills we wouldn’t gain from a textbook,” he noted. “It’s an incredible learning journey, and it’s inspiring to be part of something that could change the way people travel.”

The Role of Autodesk Fusion in the Project

One of the team’s greatest assets is Autodesk Fusion, a design platform that enables seamless collaboration and complex project management. With more than 50 team members working on different aspects of the pod simultaneously, Fusion’s cloud-based structure allows for real-time collaboration and data management. “We rely on Fusion for everything from concept sketching and generative design to simulation and assembly,” said Mootz, highlighting the platform’s utility in managing the complexities of large assemblies and maintaining design integrity.

The team’s workspace in Fusion is meticulously organized, with a folder structure that aligns with each design phase. This structure enables smooth onboarding for new team members and ensures continuity from one year to the next. “With a high turnover rate—about 80% of our team is new each year—maintaining knowledge continuity is one of our biggest challenges,” Mootz explained. The onboarding phase includes mentorship from previous members, skill-building workshops, and hands-on training in Fusion. By maintaining an organized design history, the team can preserve and build upon the work of previous years, ensuring continuous improvement with each iteration.

Innovative Design and Technical Challenges

Mootz’s presentation delved into the technical aspects of the pod, showcasing several innovative design elements. The Hyperloop pod’s aerodynamic shell, fabricated from natural fibers, minimizes drag while meeting the structural demands of high-speed travel. The shell design, Mootz explained, is optimized for both functionality and environmental sustainability, in line with the project’s green ambitions. Inside the pod, the team has integrated a double-sided linear induction motor that propels the vehicle with a moving magnetic field—a key innovation that allows the pod to reach speeds of up to 120 km/h on a short track, with potential to scale up in the future.

Another critical component is the levitation system, which uses electromagnets to lift and guide the pod along the track. “Our levitation system is based on attraction, which means the magnets pull the pod upwards rather than repelling it from the ground,” Mootz explained. This setup allows for precise control, maintaining a consistent 6-millimeter air gap between the pod and the track. A closed-loop liquid cooling system ensures that the levitation units stay within optimal temperature ranges, preventing overheating during high-speed operation.

To power the system, the team has replaced traditional batteries with lightweight supercapacitors, which provide rapid energy discharge, a crucial feature for high-speed travel. Wireless power transfer technology, developed in partnership with SEW-EURODRIVE, enables uninterrupted power flow, allowing the pod to operate continuously without needing to recharge. “This technology allows us to theoretically drive the pod indefinitely, as long as we’re within the power grid,” said Mootz.

Looking Forward: A Shared Vision for the Future

As the presentation drew to a close, Mootz shared his team’s aspirations for the future. While their current prototype operates at a modest speed, the mu-zero team envisions a Hyperloop system capable of traveling over 1,000 kilometers per hour. However, they acknowledge that significant challenges remain, from infrastructural costs to stringent safety standards. The Hyperloop Development Program in Europe, a new initiative aimed at advancing the technology, offers promising support for teams like mu-zero, providing a collaborative platform for Hyperloop research and development.

“We’re excited to be part of a larger movement that’s working to make Hyperloop a viable mode of high-speed transportation,” Mootz said. “Our work is just one piece of a global puzzle, but together, we believe we can bring this technology to life.”

Mootz closed his presentation with a rallying cry for the audience to support sustainable innovation. “Let’s create the future together,” he urged, as applause filled the room—a testament to the passion, ingenuity, and determination of a new generation of engineers ready to redefine the future of mobility.