ZF Capitalizes on Global Megatrends: World Market Leader in Car Chassis Technology

The software-defined vehicle is becoming a reality. New powerful central or domain controllers are already consolidating the control of multiple components, including key chassis functions like braking, steering and damping. “We at ZF are benefiting from this trend in two ways,” explains Dr. Peter Holdmann, Board of Management member at ZF and head of Division Chassis Solutions: “First, through the expected global rise in demand for system-ready components, such as our steer-by-wire or brake-by-wire solutions. Additionally, there is strong demand for compelling new functions that seamlessly coordinate these components and deliver great benefits to end customers.”

Chassis 2.0: Strong market position for interconnectable products

ZF's Chassis 2.0 approach leverages intelligent, interconnectable actuators to enable new chassis functions powered by software. All of these products are already part of the ZF Chassis Solutions Division's current portfolio. At the heart of this effort is the industrialization of by-wire technologies, where systems like braking and steering operate without any mechanical connection between the steering wheel and steering gear, or between the brake pedal and the brake system. At the beginning of the year, the NIO ET9 became the first vehicle on the Chinese market to go into series production with a full steer-by-wire system – developed by ZF. Two additional contracts from Chinese automakers have already been received. ZF has also secured a contract from Mercedes-Benz, with series production scheduled to begin in 2026.

ZF's Chassis 2.0 product portfolio also includes active and semi-active damping systems. The sMOTION active chassis system from ZF resolves a long-standing trade-off in passenger car chassis design: Stability and dynamics no longer come at the expense of comfort – they can now go hand in hand. ZF introduced its first semi-active CDC (Continuous Damping Control) system to the market 25 years ago. Today, ZF supplies 40 percent of the global market in this segment. The company holds an even stronger market position in rear-axle steering with its AKC system. In 2024, ZF achieved a global market share of 73 percent with this system, and even an impressive 80 percent coverage in the Asian market.

“With our Chassis 2.0 approach, we are precisely meeting today's market requirements,” states Dr. Peter Holdmann. “We anticipate that this segment of our product portfolio alone will account for approximately 33 percent of the global market by the end of this decade, generating total revenues of around €4.8 billion. We are set to establish market- and technology-leading positions across all key segments of our Chassis 2.0 portfolio.”

The Chassis 2.0 product line appeals to all customer groups, as recent orders clearly demonstrate: ZF is already securing contracts from globally active European and North American volume manufacturers, dynamic Chinese OEMs and agile start-ups targeting niche markets.

Software excellence – independent of hardware

ZF is one of the few technology partners to offer software expertise independently of whether the associated actuators are included in the scope of supply. The key to this is the cubiX software platform, which seamlessly coordinates all components involved in longitudinal, lateral and vertical dynamics through a unified control logic. It ensures harmonious vehicle motion according to the manufacturer's specifications, even when some of the chassis components installed in the vehicle do not come from ZF. The technology group already offers cubiX in series production and is now taking the next logical step with the developer tool cubiX Tuner. Designed as an intuitive solution for vehicle manufacturers, it automatically calculates the interdependencies between actuators. An electronic control unit can now be configured with the manufacturer's unique “brand DNA” in just a few clicks. This innovative tool supports engineers in the complex task of chassis calibration – delivering significant added value, particularly in terms of reducing development time. “This directly addresses a key demand from customers across all markets, particularly in Asia, to accelerate development processes and reduce costs,” explains Philippe Gasnier, Philippe Gasnier, Head of Development for the Division Chassis Solutions.

A “fitness tracker” in the chassis – powered by the synergy of data, software and control

The close integration of hardware expertise and software know-how at ZF, driven by growing demand for new chassis functions, is clearly illustrated by a current product example: the Smart Chassis Sensor. Integrated into a ball joint, it measures the relative movement of the vehicle body. The sensor and its data already enable the control of essential chassis functions. This year, it entered series production in the Cadillac CELESTIQ.

ZF's latest advancement enables the system to capture chassis acceleration in all three dimensions. Thanks to this high-resolution data, additional functions are now possible, such as those within ZF's “Chassis Health” concept: The acceleration data from the Smart Chassis Sensor continuously record the forces acting on the chassis and vehicle body. Algorithms then calculate in real time how these events could impact chassis functionality. The interaction between hardware and software enables continuous real-time monitoring of chassis component conditions. The data transmitted via a vehicle cloud connection is transferred through standardized interfaces and analyzed using AI-powered algorithms. This solution provides critical insights into mechanical loads and safety-relevant conditions of the chassis – essentially acting as a “digital fitness tracker” for the vehicle. Integrated in backend systems, ZF's “Chassis Health” concept enables data-driven development while helping to reduce unplanned downtime and workshop visits.

At the Chassis Tech Day 2025 in Friedrichshafen, ZF shows its expertise and chassis technology portfolio using test vehicles and production models. For the first time in Europe, visitors will also have the opportunity to experience a NIO ET9 – owned by ZF – firsthand. For this vehicle, ZF supplies both the steering wheel actuator – responsible for steering and delivering the desired steering feel – and the redundant steering gear actuator, along with the corresponding software which NIO developed jointly with ZF. As a result, the Smart Electric Executive Flagship operates without a mechanical connection between the steering wheel and the front wheels.