Development | Simulation | Design
We are your development partner for the design and engineering of complex components and assemblies in the industrial sector. Our engineering services cover design, calculation and simulation, and are tailored to the demands of modern product development.
The focus is on production-oriented development, taking into account installation space, mechanical and thermal loads, and material properties. In doing so, we combine design expertise with a deep understanding of real-world operating conditions and industrial manufacturing processes.
We support the entire development process – from conceptual design and structural implementation through to validation and transition to series production. The aim is to develop technically robust and economically viable solutions that can be reliably integrated into existing production processes.
A particular focus of our long-standing development work lies in the field of components subjected to high thermal loads, particularly in the design and construction of exhaust systems. This expertise is also applied to other areas of application, enabling robust, practical solutions.
Through the close integration of development, prototyping and manufacturing, we ensure that designs are not only optimised in theory but can also be reliably implemented under real-world conditions.
On request, we can provide on-site support and integrate flexibly into your existing development structures.
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Engineering for exhaust systems
Modern exhaust systems must meet a wide range of requirements:
- thermal resilience at high temperatures
- optimal airflow management
- integration into confined spaces
- compliance with emission and noise standards
- weight optimisation
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Development expertise in practice
Thanks to our many years of experience in the development of exhaust components, we have in-depth expertise in:
- Design of complex pipe and exhaust systems
- Optimisation of installation space in vehicle applications
- Selection of materials for components exposed to high temperatures
- Design for manufacturing
- Integration of components into existing systems
- Lightweight construction
- Redesign of exhaust systems and manifolds
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Operational vibration analysis (OVA)
We carry out operational vibration analyses to assess the dynamic behaviour of components and systems in real-world operating conditions.
- Analysis of vibration behaviour and natural frequencies
- Identification of critical resonance ranges
- Assessment of vibration excitation caused by operating conditions
- Development of design optimisation measures
The aim is to detect and prevent vibration-related damage at an early stage and to ensure long-term durability under real-world operating conditions.
Forming simulation (hydroforming & deep drawing)
We rely on simulation-based methods for the design of forming processes:
- Analysis of material flow and wall thickness distribution
- Prediction of wrinkling and cracking
- Optimisation of tool and process parameters
This enables the reliable and cost-effective production of complex geometries.
CFD calculation (fluid flow simulation)
We use CFD simulations to analyse flow conditions within components and systems.
- Optimisation of flow patterns and pressure loss
- Analysis of temperature distributions
- Assessment of gas and fluid flows
This is particularly relevant for applications involving thermal and fluid dynamics requirements.
Thermomechanical Analysis & Hot Gas Testing
For components subjected to high loads, we combine thermal and mechanical simulations to provide a realistic assessment of component behaviour.
- Simulation of temperature cycles and thermal expansion
- Assessment of thermally induced stresses
- Verification under realistic load conditions
In addition, hot-gas tests enable validation under real-world conditions.
Rapid Prototyping für fast product development
Thanks to the close integration of in-house design, our own toolmaking facilities and comprehensive production expertise, we are able to produce prototypes quickly – within a matter of weeks, depending on the complexity.
Our integrated processes enable rapid iterations and adjustments right from the early stages of development. This helps to shorten development times and efficiently validate technical solutions.
From design and toolmaking through to manufacturing, all steps are seamlessly integrated. This ensures that prototypes are not only available quickly, but also function under real-world conditions and can be transferred to series production.
In our in-house design department, fixtures of all kinds, as well as tools for production, are designed in consultation with the development team and in accordance with the relevant customer specifications.
Reverse Engineering
A key component of our development processes is the reverse engineering of existing components or systems. This involves capturing the geometry of existing components, re-engineering them, and converting them into a production-ready CAD model. This enables the targeted analysis, optimisation or reproduction of components even without complete original design data.
In addition, for rapid prototyping we rely on additive manufacturing using 3D printing (plastics). This allows geometrically complex components to be produced quickly and cost-effectively and functionally validated at an early stage.
The combination of reverse engineering, 3D printing and conventional manufacturing creates an efficient foundation for rapid development cycles. Adjustments can be directly implemented in the design, tested iteratively and converted into physical prototypes.
Our integrated processes – from digital capture through design to manufacturing – enable short iteration times and a high level of technical validation even in the early stages of development.
This results in functional prototypes that are not only available quickly but can also be tested under real-world conditions and seamlessly transitioned into series production.