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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 higher efficiency, stability and product reliability, while reducing the need for costly physical 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 a 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.

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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.
Book a consultation

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
Speak to our experts

phone

E-mail

Book a consultation

Online Booking

value for money

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.

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
Speak to our experts

phone

Email

Book a consultation

Online Booking

value for money

Contact
Contact