ProFlex

Development of Intelligent Manufacturing Processes for an Innovative Flexible Drive Shaft Based on Novel Material Combinations to Significantly Increase Market Potential

In collaboration with its project partners, NEMOS has developed the flexible drive shaft N‑Flex, based on a novel hybrid material concept combining fiber‑reinforced composites and elastomers. This already patented, disruptive lightweight solution enables the transmission of high torque while offering exceptional misalignment and displacement capability. As a result, heavy couplings or joints can be eliminated, achieving a weight reduction of more than 50% compared to conventional drivetrain systems.

Initial prototypes have already been successfully deployed in the high‑end maritime sector. However, both technical and economic challenges currently limit access to broader markets. The ProFlex project therefore pursues two key objectives: on the one hand, the development of a manufacturing process for longer and more bending‑stiff shafts to address additional market segments within the maritime industry. On the other hand, to enable entry into the industrial mass market, a highly automated and cost‑efficient production process based on new material combinations will be developed.

The work of the three project partners is supported by two suppliers of key materials, as well as by end users who will enable pilot applications in both target markets as part of the project.