This paper presents the design process and resulting technical concept for an integrated hyperloop system, aimed at realizing efficient high-speed ground transportation. This study integrates various functions into a coherent and technically feasible solution, with key design decisions that optimize performance and cost-efficiency. An iterative design process with domain-specific experts, regular reviews, and a dataset with a single source of truth were employed to ensure continuous and collective progress. The proposed hyperloop system features a maximum speed of 600 $\frac{\mathrm{km}}{h}$ and a capacity of 21 passengers per pod (vehicle). It employs air docks for efficient boarding, electromagnetic suspension (EMS) combined with electrodynamic suspension (EDS) for high-speed lane switching, and short stator motor technology for propulsion. Cooling is managed through water evaporation at an operating pressure of 10 $\mathrm{m}$$\mathrm{bar}$, while a 300 $\mathrm{k}$$\mathrm{W}$ inductive power supply (IPS) provides onboard power. The design includes a safety system that avoids emergency exits along the track and utilizes separated safety-critical and high-bandwidth communication. With prefabricated concrete parts used for the tube, construction costs can be reduced and scalability improved. A dimensioned cross-sectional drawing, as well as a preliminary pod mass budget and station layout, are provided, highlighting critical technical systems and their interactions. Calculations of energy consumption per passenger kilometer, accounting for all functions, demonstrate a distinct advantage over existing modes of transportation, achieving greater efficiency even at high speeds and with smaller vehicle sizes. This work demonstrates the potential of a well-integrated hyperloop system to significantly enhance transportation efficiency and sustainability, positioning it as a promising extension to existing modes of travel. The findings offer a solid framework for future hyperloop development, encouraging further research, standardization efforts, and public dissemination for continued advancements.

Rapid prototyping has become increasingly popular over the past years. However, its application is heavily confined to a part size that fits the small build volume of additive machines. This paper presents a universal design method to overcome this limitation while preserving the economic advantages of rapid prototyping over conventional processes. It segments large, thin-walled parts and joins the segments. The method aims to produce an assembly with minimal loss to the performance and characteristics of a solid part. Based on a set of requirements, a universal segmentation approach and a novel hybrid joint design combining adhesive bonding and press fitting are developed. This design allows for the force transmission, positioning, and assembly of the segments adaptive to their individual geometry. The method is tailored to fused deposition modeling (FDM) by minimizing the need for support structures and actively compensating for manufacturing tolerances. While a universal application cannot be guaranteed, the adaptive design was proven for a variety of complex geometries. Using automotive trim parts as an example, the usability, benefits, and novelty of the design method is presented. The method itself shows a high potential to overcome the build volume limitation for thin-walled parts in an economic manner.