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.

The hyperloop concept envisions a low pressure tube and capsules, called pods, traveling at the speed of commercial aircraft as a sustainable, future-proof mass transportation system between cities. However, in contrast to the use case of such a system, the detailed technical concept is still under development. One challenging difference in comparison to other modes of transportation lies in the technical concept of the infrastructure, which is hard to change in the long term and therefore allows a few iterations only. This study’s key contribution is to showcase the conceptual design decisions of the 24 m full-scale Hyperloop Demonstrator at the Technical University of Munich (TUM) for the propulsion and suspension system, featuring the design decision tree (DDT) method as a framework to visualize and explain the technical design decisions and dependencies of complex hardware systems. The construction of the full-scale demonstrator not only proved the feasibility of the concept but also provided valuable concept-level experiences, which are shared within this work. Compared to existing maglev and hyperloop concepts, the presented concept features a separated air-cored long stator propulsion system and a homopolar electromagnetic suspension at the bottom with the track wrapping around the vehicle, revealing promising advantages like the structural simplification of the infrastructure and the independence of the guideway and tube.