Our areas of competence to your benefit

Complex prototype projects demand more than conventional approaches. You need a partner who masters cutting-edge engineering disciplines. With expertise in flow and cooling optimization, combustion analysis, AI-driven modeling, and prototype development, Felsaris delivers integrated solutions that accelerate innovation. This way, you secure lasting competitive advantages.

Flow Optimization

We provide advanced flow analysis and design optimization to unlock higherefficiency, stability and product reliability, while reducing the need for costlyphysical prototypes.

Investigation and reduction of flow separation and pressure losses

Performance increase through optimized flow channels and component geometries

Valve flow optimization for higher throughput and reliability

Aerodynamic design for cars, airfoils, drones and boats

Drag reduction and lift optimization for efficiency and stability

CFD simulations for internal and external flow applications with high accuracy

Flow-induced noise analysis and reduction for improved comfort and
compliance

Results: Faster development cycles, fewer prototypes and measurable performance improvements that translate directly into cost efficiency and market advantage.

Prototype Development

We create tailored prototype solutions from first concept to pre-series stage, combining digital engineering with rapid manufacturing to reduce development risks and accelerate decision-making.

Development of functioning prototypes ready for testing and validation

Design support for concept, prototype and pre-series stages

3D scanning, digitization and reverse engineering of existing components

3D printing (FDM, SLA/DLP) and conventional manufacturing methods

Design renderings and visualizations for clear decision-making

Bill of materials creation and cost estimation for transparency

Rapid iteration cycles with virtual validation using CAD, CFD and FEM

Results: Reduced time-to-market, lower development costs and reliable prototypes that accelerate innovation and investment decisions.

Combustion & Emissions

We support the development of advanced combustion systems by combining chemical reaction modeling with high-fidelity simulations to improve efficiency, reduce emissions and validate innovative concepts.

Selection and validation of reaction mechanisms using Cantera

Proof-of-concept studies for novel combustion processes

Combustion simulation for gaseous and liquid fuels

Emissions prediction (NOx, CO, unburned HC)

Design of low-emission combustion systems for H₂, syngas and

biofuels

Optimization of burner, combustor and chamber geometries

Definition of emission reduction strategies for product development

Results: Cleaner, more efficient combustion systems with validated emissions performance, enabling compliance with regulations and accelerating the adoption of sustainable fuels.

Cooling

We design and validate advanced cooling concepts to ensure reliability, efficiency and compactness across a wide range of applications, from electronics to mobility systems.

Thermal simulation for electronics, batteries, fuel cells and e-motors

Hot spot investigation and elimination of local overheating risks

Heat exchanger and radiator optimization for maximum efficiency

Simulation of transient thermal behavior under dynamic loads

Coupled CFD and FEM analyses for thermal-structural interaction

Development of HVAC and heat pump systems

Lightweight and compact cooling solutions optimized for performance and packaging

Results: Reliable thermal management with reduced component stress, longer lifetime and compact solutions that save weight, space and cost.

Hydrogen Combustion Engine (H2ICE)

We support the transition from fossil fuels to hydrogen-powered mobility by developing, simulating and validating hydrogen combustion engines with focus on efficiency, durability and zero-emission operation.

Hydrogen retrofit and fuel conversion strategies for existing engines

Turbo-matching and charging strategy optimization

1D engine process simulations for performance prediction

Pre-ignition and knock mitigation strategies for stable operation

Gas exchange and intake/exhaust system optimization

Combustion simulations with CFD and Cantera

Engine testing up to 750 kW for validation under real conditions

Cylinder head and valve train optimization for H₂ operation

Fuel injection and ignition system analysis for reliable combustion

Results: Ready-to-run hydrogen engines with full power output, zero CO₂ emissions and validated performance – enabling fast prototyping and market entry for sustainable mobility solutions.

Machine Learning - AI

We integrate artificial intelligence into engineering workflows to accelerate development, improve design quality and reduce the need for costly trial-and-error iterations.

Surrogate modeling for

fast and accurate performance prediction

Automated data analysis and pattern recognition from large datasets

Reinforcement learning methods for intelligent design exploration

Integration of ML into existing simulation workflows

AI-assisted design optimization in CAD and CFD environments

Development of correlation models to reduce design variants and speed up decision-making

Results: Faster innovation cycles, fewer physical prototypes and data-driven design decisions that lower development costs and open new performance potentials.

Ready to bring your idea to life?

Contact us to receive a personalized offer for your project — or see if our flexible CAD/CFD on-demand solutions are the right fit to get you started quickly.

CFD Development Expertise On Demand

Immediate simulation capacity and planning reliability for your development project. Our experts from advanced engineering and motorsport support you in optimizing fluid flow, engine performance, turbo matching, cooling efficiency, pressure loss, supplier coordination, and much more. When required, we use our own software and computing infrastructure, allowing you to access state-of-the-art simulation results without making any upfront investments.

Starting from

€6,000

plus VAT

No minimum contract term
Detailed reports with optimization recommendations
Assessment of flow and cooling potential
Support in setting up your own CFD department and best practices
Engineering services starting at 70 hours/month
On-site deployment and integration into your processes if required
We can provide our licenses (StarCCM+, GT Suite) if needed
HPC hours are billed separately if required
Credit for previous payments when converting to a large project
Parallel, free review for securing funding

Phone

+49 171 9466327

Email

info@felsaris.com

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