Simulation services Mannheim

Evaluate flow, cooling and drive systems even before the prototype.

Felsaris makes technical risks visible before time and budget are invested in prototypes, test benches, or test series. Pressure losses, overheating risks, unfavorable flow patterns, and system behavior can thus be assessed early and specifically improved.

Development time
- %
Prototype costs
- %
Prediction accuracy
+ %

The challenge

Physical tests cost time, money, and nerves.

Product development in mechanical and automotive engineering keeps getting more complex: more variants, stricter requirements, tighter budgets. At the same time, the demands on development speed, degree of innovation and technical validation continue to rise. This is exactly where we come in – with CAD design, CFD simulation and FEA analysis that validate decisions early instead of correcting them expensively at the prototype stage.

Too many
prototype loops

Design decisions are often only validated after prototypes have been built. Each additional iteration incurs additional time and costs.

Late
fault detection

Pressure losses, overheating risks, unfavorable airflow patterns or other technical weaknesses are often only discovered when modifications have already become expensive.

Lack of
simulation capabilities

Complex simulation projects require specialized CFD expertise and sufficient capacity, which is not always readily available in everyday development work.

High
pressure to develop

Shorter development cycles and increasing competitive demands are increasing the pressure to secure technical decisions early on.

Limited transparency
in system behavior

Without digital simulation, critical areas such as pressure losses, flow separation, temperature peaks or uneven flow patterns often remain hidden.

High approval
and testing costs

Test benches, test series and release processes are cost-intensive and tie up resources that are needed for the further development of new products.

The solution

Simulations create transparency before high costs arise for prototypes, test benches or late design changes.

Felsaris handles the complete engineering simulation for your development project: from initial modeling to validated results and supplier contact.

Simulation vs. physical test

Cost per iteration

simulation

Physically
Time until result

simulation

Physically
Iterations possible

simulation

Physically
sustainability

simulation

Physically

MEASURABLE BENEFITS

What you will specifically gain

Shorter development time
- %
Iterations in the digital model take hours, not weeks. Your product will reach the market sooner.
Lower prototype costs
- %
Physical test samples are reduced to a minimum and serve only for final validation and verification.
Prediction accuracy
+ %
Validated CFD models deliver results your development team can trust
Any number of variations
Test 10, 50 or 200 design variations without additional material costs.

Use Cases

Where simulation makes the difference: these examples show the questions our clients brought to us and the results they ended up with – concrete, verifiable and taken from real projects.

Services in detail

Virtual development for flow, thermal management and propulsion

Whether it’s flow simulation, thermal management, aerodynamics, engine development or virtual system simulation: Felsaris supports development projects from the initial concept evaluation to technical validation.

3D CFD Simulation

Flow simulation & pressure loss analysis

Analysis of air, gas, and liquid flows to optimize throughput, pressure losses, and flow guidance. Critical flow zones, uneven flow patterns, and thermal hot spots become visible even before the first prototype.

AERODYNAMICS & EXTERNAL FLOW

Optimization of air resistance, lift and flow conditions

Aerodynamic design of vehicles, drones, wings, and technical systems. The focus is on drag, lift, airflow patterns, and flow separation to improve efficiency and stability.

DRIVE SYSTEMS

Engine development & system simulation

Development and optimization of combustion and hydrogen engines using 1D system simulations. This allows for the evaluation of air path, charging, combustion, thermal management, as well as pressure and temperature profiles in the overall system.

Cooling & Thermal Management

Cooling and thermal
design

Thermal design of electronics, batteries, fuel cells, and electric motors. Temperature distributions, heat flows, and cooling concepts are evaluated to prevent overheating and thermal weak points.

Application areas

Industries we work for

Our clients rely on our cross-industry expertise in automotive, aerospace, energy, and mechanical engineering. We transfer proven methods from high-tech industries into tailored development projects, delivering solutions that create a lasting technological edge.
  • Innovative prototype realization
  • CAD engineering & CFD simulation
  • Fluid flow and cooling optimization
  • Combustion process development
From scientific research to motorsport and pre-series development, we have successfully delivered numerous complex projects. For advanced challenges, we apply state-of-the-art correlation models, mathematics, machine learning, and AI. This shortens development cycles, boosts performance, and integrates seamlessly into your R&D processes.
Your success is our top priority.

Automotive

Aerodynamic optimization, radiator design, cooling of battery, engine, fuel cell, electric motor, performance evaluation ICE, injection simulation, retro-fit, thermal comfort in cabine, etc.

Aerospace

Aerodynamics, Drones (e.g. stability), de-icing, jet engines, SAF combustion analysis, supersonic investigations, wind tunnel, thermal comfort in cabines, etc.

Mechanical Engineering

Dryer, kilns, valves, stirrer, tank filling/ sloshing, pressure loss reduction, vacuum cleaner, agricultural machines, electronics, etc.Diagnostic products in health care are explicitly excluded.

Energy & Infrastructure

Piping, pumps, incinerator, pressure storage, water/gas turbines, sewerage systems, wind turbine blades, CHP systems, ATEX certification, etc.

Why Felsaris

Experience that counts

Experience from research and industry

Project experience in automotive, motorsport, energy and mechanical engineering applications with high demands on performance, efficiency and reliability.

Interdisciplinary systems perspective

Flow, thermal management, aerodynamics and propulsion systems are analyzed as a coherent overall system in order to make interactions visible at an early stage.

Flexible project support

From individual simulations and feasibility studies to long-term support of ongoing development projects.

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 certainty for your development project. Our experts from pre-development and motorsport will help you optimize flow, engine performance, turbo matching, cooling capacity, pressure loss, supplier communication, and much more. If required, we use our own software and computers, so you don’t have to make any investments and can still access state-of-the-art simulation results.
away
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

Value For Money