CAE

Our department does not perform partial tasks; we deliver multidisciplinary system optimization. With engineering precision, we resolve technological conflicts—such as those between weight reduction, structural stiffness, and manufacturing costs—before they escalate into critical issues.

Core pillars of our services:

• Cost control through virtual validation: By integrating simulations at an early stage, design flaws are identified in the digital environment. This prevents the exponential increase in modification costs that typically occurs during the prototype phase or shortly before series production.
• Guaranteed test success: The accuracy of our numerical models ensures that physical tests—whether static load cases or complex crash analyses—focus on documenting already validated results rather than uncovering errors. This minimizes defective prototypes and failed homologation tests.
• Mathematics-based product optimization: We do not merely verify compliance with standards; through iterative processes, we determine the true technical optimum. Along the constraints of mass, strength, and manufacturability, we ensure maximum performance with minimal material usage.

Vehicle Development

CAE / Testing

The value of an engineering solution lies in its practical feasibility. Our comprehensive testing portfolio and accredited laboratory background guarantee that digital models deliver the expected performance in reality.

• Hybrid testing ecosystem: Whether material testing, component-level measurements, or full-system testing, we treat the virtual and physical worlds as one integrated system. This enables early-stage, validated evaluation of real-world scenarios.
• Accredited measurement technology: Our in-house testing laboratories ensure measurement accuracy and traceability—essential prerequisites for type approval (homologation) and liability compliance.
• Closed-loop development: Data from physical tests is directly fed back into our CAE models. This continuous refinement enables our simulations to predict safety metrics, structural strength, and service life with exceptional reliability.

Our services include, among others:

Structural Integrity and Durability

• Stiffness, strength, and static load capacity analysis
• Misuse simulation
• Fatigue and service life analysis based on operational load cycles
• Topology and shape optimization for weight reduction

Dynamics and NVH

• Vibration diagnostics and acoustic (NVH) optimization
• Modal and frequency analyses
• Noise and vibration protection for electric powertrains

Vehicle and Occupant Safety

• Structural dimensioning and development of energy-absorbing zones
• Crash analysis of structures
• Integration of occupant protection and restraint systems (airbags, belt tensioners)
• Pedestrian protection (active and passive systems)
• Structural protection and crash safety of battery packs
• Virtual dummy modeling and biomechanical injury analysis

Thermal and Fluid Dynamics (CFD)

• Thermal management and HVAC efficiency studies
• External aerodynamics and drag optimization
• Development of cooling strategies for electronic components

Specialized and Complementary Areas

• Non-destructive simulation of composite and hybrid materials
• Manufacturing process simulation (e.g., injection molding or forming effects on final strength)
• Interference analysis in vehicles
• Sensor integration studies (impact of vibration and temperature on autonomous system sensors)

Industrial Solutions

Our strictly validated numerical methods from the automotive sector are directly transferable to other high-precision industries:

Medical and Biomechanics

• Strength and durability analysis of implants (e.g., hip, knee, dental implants)
• Deformation analysis of vascular devices
• Ergonomic and structural optimization of surgical instruments
• Biomechanical simulations of human tissue–material interaction

Mechanical Engineering and Heavy Industry

• Static and dynamic analysis of large castings and welded machine frames
• NVH diagnostics of gearbox housings and rotating machinery
• Load analysis of agricultural and earthmoving machinery

Steel Structures and Construction

• Load-bearing analysis of cranes, supporting structures, and special containers
• Seismic (earthquake safety) analysis
• Wind load and fluid-dynamic studies on high-rise buildings and bridges

Aerospace and Shipbuilding

• Structural dimensioning of lightweight frames and composite elements
• Hydrodynamic and structural integrity analysis of ship hulls under wave loading

Consumer Electronics and Household Appliances

• Drop testing of mobile devices (phones, tablets)
• Fatigue testing of connectors and flexible printed circuit boards
• Noise and vibration reduction in household appliances
• Thermal optimization of electronic heat sinks and fans

Defense and Special Applications

• Impact analysis of ballistic protection systems and armored structures
• Modeling structural effects of blast shock waves

Additional Services

Project and Supplier Management

• Strategic leadership from concept to series production
• Quality assurance of supplier data and assembly of integrated models
• Definition and monitoring of technical requirements

Validation and Laboratory Infrastructure

• Full test coordination in our accredited German laboratories
• Virtual–physical correlation analysis (mathematical comparison of simulation and measurement data)
• Design of custom test rigs for specialized component testing

Software and Hardware Strategy (CAE Infrastructure)

• Application and consulting in industrial-standard software environments:
  • Pre-processing: Ansa, HyperMesh
  • Solvers: Abaqus (static/nonlinear), LS-DYNA / Pam-Crash (explicit dynamics/crash), Epilysis, Nastran (linear statics/NVH)
  • Post-processing: Meta, Animator
• Development of custom automation scripts (Python/C++) to accelerate simulation workflows
• High-performance computing clusters

System-Level Simulation and Certification

• Complex finite element analysis and multi-body dynamics
• Virtual support for authority homologation (type approval)
• Sensitivity and robustness analysis considering manufacturing tolerances

What Our Colleagues Say About Crash Testing

The essence of crash simulation is not destruction, but energy management. Whether it is a vehicle collision, an aircraft emergency landing, or a mobile phone drop, the objective is always the same: to protect critical content—human life or technology.

Our approach: We use explicit dynamic simulations to model material behavior under extremely high strain rates. We analyze the energy absorption capacity of crumple zones and fracture processes.