The Bionik‑Hackathons project ran from 1 November 2021 to 30 June 2023 under the German Federal Ministry of Education and Research funding (grant number 13XP5143) and was organised by BIOKON e. V., a research consortium that brings together scientists from diverse disciplines within the Bionik‑Competence Network. Three industrial partners served as “industry mentors”: J.M. Voith SE & Co. KG from the paper sector, Brose Fahrzeugteile SE & Co. KG from the automotive sector, and Joyson Safety Systems Aschaffenburg GmbH, also automotive. The project’s aim was to apply biological principles to concrete engineering challenges posed by these partners through a series of seven extended hackathons, followed by a “plus‑phase” of prototyping and feasibility studies carried out in the partner companies.

During the first hackathon the team focused on the refining step of paper production. By analysing biological models of fibre separation and self‑cleaning surfaces, participants proposed surface chemistries that reduce adhesion of pulp fibres to equipment, thereby lowering energy consumption and water usage. The resulting design was tested in a pilot‑scale refining unit, showing a reduction in chemical consumption of 12 % and a 5 % decrease in CO₂ emissions compared with the baseline process. In the second hackathon, the group tackled the design of form‑stable airbags. Drawing inspiration from the flexible yet resilient structures of insect wings, they developed a composite material that maintains its shape under high pressure while using 30 % less material than conventional airbags. Mechanical testing confirmed that the new design met all safety certification requirements for frontal impact.

The third hackathon addressed airbags for lying passengers, a niche safety requirement for autonomous vehicles. By mimicking the load‑distribution patterns of animal joints, the team created a multi‑layered cushion that can be deployed in a reclined position without compromising structural integrity. Bench‑scale tests demonstrated that the cushion could absorb impact forces equivalent to a 30 km/h collision while occupying 20 % less volume than existing solutions.

In the fourth hackathon, the focus shifted to the paper machine itself. Participants developed a self‑cleaning coating inspired by lotus leaves, which was applied to the surface of the paper‑making rollers. The coating reduced fouling by 40 % during a 48‑hour continuous run, cutting maintenance downtime and cleaning costs. The fifth hackathon produced alternative door systems for public transport vehicles. By emulating the hinge mechanisms of certain arthropods, the team designed a door that requires 25 % less actuation force and can be manufactured with a lighter frame, thereby reducing vehicle weight by 3 % and improving energy efficiency.

The sixth hackathon explored assistive devices for people with reduced mobility in public transport. A bio‑inspired hand‑hold system, modeled after the grip patterns of primates, was developed. Prototyping showed that the system could support a 120 kg load with a safety factor of 2.5, meeting accessibility standards. Finally, the seventh hackathon tackled the design of a front trunk (“frunk”) for electric cars. Using the structural principles of bird bones, the team created a lightweight, impact‑resistant enclosure that adds only 1.5 % to the vehicle’s overall weight while providing 15 % more usable space than conventional designs.

Throughout the project, the hackathon format encouraged rapid ideation, sketching, and the creation of functional models on site. The subsequent plus‑phase allowed the most promising concepts to be refined, prototyped, and tested in real‑world settings within the partner companies. The collaboration model combined the breadth of academic expertise with the practical constraints of industry, enabling a focused, “research‑on‑the‑point” approach that accelerated the translation of bio‑inspired ideas into viable engineering solutions. The outcomes of the project are documented in the final report and will be disseminated through peer‑reviewed publications and industry presentations, ensuring that the knowledge gained benefits both the scientific community and the participating companies.