Safe, flexible and ready for the future
Sonplas delivers safe and flexible testing solutions for modern propulsion technologies
The development of modern propulsion systems is increasingly shaped by diversity. Alongside conventional fuels, hydrogen, methanol, and ammonia are moving into sharper focus. For manufacturers, this means testing processes must be safe, flexible, and future-ready. Sonplas supports this transformation with modular test solutions for fuel-contact components—engineered to meet the requirements of today and tomorrow.
Based in Germany, Sonplas develops custom test systems that help customers validate new fuels early and with confidence. The goal is to reduce development risk, accelerate decision-making, and ensure a safe, reliable transition from development into series production. “We’re currently developing a complete test center for methanol and ammonia applications for one of our customers,” says Werner Riederer, Sales Manager, Fuel Technology at Sonplas. “It’s not just about the test system itself, but about managing the entire project.”
Sonplas supports customers from the initial concept through commissioning of the system. This includes assistance with regulatory approvals and acceptance testing,
as well as consulting on safety and operating concepts. Especially when working with new fuels or initial applications, this holistic approach builds trust and provides the planning certainty customers need. “For many customers, this is new territory,”
explains Werner Riederer. “Our role is to make sure they can rely on proven solutions and experienced partners.”
Practical Testing Under Real-World Conditions
With more than 30 years of experience testing fuel-contact components, Sonplas brings a strong foundation from the automotive industry and successfully applies it to sectors such as aerospace, maritime applications, and electromobility.
The test systems enable realistic testing under variable conditions. Components can be tested for flow, pressure, leak tightness, and service life, both for liquid and gaseous media. In addition, environmental parameters such as temperature, humidity, and air pressure can be simulated to assess component performance under real-world operating conditions.
An in-house development laboratory further supports customers with feasibility studies and product testing. This enables
test procedures to be specifically adapted to new applications and delivers reliable, actionable results at an early stage.
Through functional and durability testing, Sonplas ensures that components operate reliably in series production.
Safety as a Key Driver of Market Success
Working with alternative fuels places stringent demands on safety and operating concepts. Sonplas takes a holistic
approach to system development—from the design of the test system through to its integration into the surrounding environment. The goal is to minimize risk and ensure safe, reliable operation.
“Our customers especially value our consulting support,” emphasizes Werner Riederer. “A safe test system isn’t defined
by technology alone—the surrounding environment has to be right as well.” On this basis, Sonplas delivers solutions
designed for long-term viability—providing a solid foundation for sustainable investment decisions.
With many years of experience in testing, Sonplas is continuously expanding its test systems to meet the requirements of new fuels. Shown here is a methanol endurance test bench for injectors.
Hydrogen in Focus
Hydrogen plays a central role in future energy systems. It is crucial for manufacturers of electrolyzer and hydrogen components to test their products at an early stage under conditions that closely resemble series production. Sonplas combines its testing capabilities with expertise in power electronics to support customers in the development and validation of new systems.
On request, the company delivers complete hydrogen testing infrastructures—from individual test systems to full test centers, including secure containerized solutions for operation.
Test Benches for Individual Electrolysis Cells and Short Stacks
Sonplas develops and builds test benches for individual electrolysis cells and stacks. These are the core components of electrolysers used for hydrogen production. The test bench concept allows for the testing of various technologies—including proton exchange membrane (PEM) electrolysis, alkaline electrolysis (AEL), and anion exchange membrane (AEM) electrolysis. The focus is on a modular design of the system for different performance classes and measurement configuration levels, which can be adapted to customer needs. Target applications include both tasks at research institutions for basic research as well as investigations at industrial customers in pre-production and series development.
Test system for gasoline injectors: Supports spray and flow testing, leak testing, and optical inspections.
Modular. Scalable. Custom-Engineered.
With more than 1,000 systems delivered worldwide and an international service network, Sonplas is an established partner for demanding testing applications. Each system is individually designed and modular in structure to ensure flexibility in meeting new requirements.
“Our commitment is clear,” summarizes Werner Riederer. “We support our customers in bringing their products to market safely, efficiently, and with a clear focus on the future.”
