We provide native 3D models and drawings for CAD software such as Siemens NX and CATIA. Of course, we take into account the OEM-specific standards for model creation. If desired, we are able to enter the data directly into the customer’s product data management system, for example via remote desktop.

In some cases, reference parts are available as hardware. We use reverse engineering to transfer these to the 3D model, where they can be redesigned to meet requirements. To achieve the weight targets, we use topology optimization. In addition, we prove the component properties with the help of extensive FEM investigations.

We design components ready for production and assembly depending on the area of application. In addition to forming, shaping and classical machining, we also design components for additive manufacturing (metal 3D printing). The design is carried out in close coordination with our long-standing suppliers (from manufacture to Tier1). Thanks to our network, we can also provide high-quality hardware at short notice.

By means of topology optimization, we design components even before the actual calculation with special attention to the weight or stiffness targets. We achieve particular success with milled and cast parts such as wheel carriers, control arms and swing arms. Thus, within the available installation space, material is only used along the relevant load paths. The result is an organic functional design of the components. For optimization, we use Altair Inspire, among others.

The finite element method (FEM) enables the simulation of material behavior within individual components. The result is proof of the component’s functionality in the desired usage scenarios or load cases. The load data can be determined externally or at TRE. The model meshing, definition of boundary conditions and calculation is covered by a proven tool chain. These include Abaqus, ANSYS, FemFAT and the ANSA pre-processor.

The core objective of the investigation is to prove the strength of the components. The fatigue strength can also be determined and evaluated. Furthermore, we determine the component stiffness. The study is rounded off by various frequency analyses. We provide the output in the form of a Modal Neutral File (MNF) for further investigation in Multi Body Simulation.

From single pieces to small series, we realize the production in our in-house workshop. With great expertise in welding technology, we manufacture welded assemblies from steel, stainless steel and aluminum – from simple sheet metal brackets to control arms and axle carriers to complete vehicle tubular frames. We adapt series parts for use in the prototype. We also handle the necessary fixture construction internally.

In our composites workshop, we laminate flat components with glass fiber, carbon fiber and aramid reinforcement using the vacuum infusion process. This is how exterior and interior trim, aerodynamic components, battery housings and other parts are produced. The mold construction is realized by our long-term partners.

We supply you with completely assembled assemblies and axis modules. We rebuild the body of the carrier vehicle to provide functional aggregate carriers.

Measuring equipment includes a Stiefelmayer coordinate measuring machine (6m x 3m x 2m), a Romer 3D measuring arm and a chassis measuring system. With these devices we cover both tactile and optical measurement. Examples include the axle kinematics of a reference vehicle, 3D scans of components and the quality assurance of our components as measurement tasks. The PolyWorks software serves here as an interface to the CAD environment.