AUTOMOTIVE
Automotive pedal assembly
Accelerator pedal with a position sensor: kinematics, packaging and mountings designed in CAD.
DESIGN · FEM ANALYSIS · PRODUCTION
We design, validate with FEM analysis and produce your special components.
From a hand sketch or a spec through to the finished part: mechanical design and finite element simulation with Ansys, SolidWorks and MATLAB (static, fatigue, thermal and vibration), with a single technical lead.
From requirement to validation report
Four phases and one technical lead, from the first calculation to the tested part.
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Design
We start from the functional requirements, the constraints and on-site surveys, and design the component or assembly from concept to production drawing.
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FEM analysis
We validate behaviour with finite element analysis: static, fatigue, thermal and vibration, with stresses, deformations and safety factors.
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Production
We take the project into production, also with qualified partners, keeping the critical dimensions under control. Technical responsibility stays with us.
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Testing and validation report
We verify the real part with bench tests, strain gauges and optical measurements, and deliver the conformity report with the technical dossier: assumptions, model, tests and checks.
This approach, applied end to end on a real case
A carbon-fiber foot prosthesis: designed, optimised with over 1,000 FEM simulations, produced, instrumented and bench-tested to ISO 10328, through to the validation report.
From CAD: some of our designs
Models and renders of real projects, across very different component types.
AUTOMOTIVE
Cabin ventilation ducts
Ducts for a cabin cooling system, designed around packaging and flow constraints.
E-MOBILITY
Modular battery pack
Modular architecture for cylindrical cells: structure, plates and fixings designed for assembly and maintenance.
Models of real projects, shown in anonymised form: customer projects remain confidential.
FEM ANALYSIS
Verified before production
We don’t stop at the drawing. Before production we check behaviour with finite element analysis, from a single component to the complete chassis of a vehicle, with real operating loads and constraints. It’s the method we refined in research: on the MyFlex-γ prosthesis, over 1,000 simulations and prototype stiffness curves matching the model.
- FEM model on real loads and constraints: nonlinear static analyses, contacts, thermal transients
- Stresses, deformations and safety factors (Von Mises; Hashin 3D and Tsai-Wu for composites)
- Optimisation with design of experiment and genetic algorithms
- Thermal, fatigue and vibration checks where needed
- Ansys, SolidWorks and MATLAB for simulation, CAD and optimisation
- Structured, complete analysis report, ready for customers and certification bodies
Main sectors we work in
- Automotive
- Hydraulics
- Industrial machinery
- Biomedical
- Sport
- Marine
Design examples
Three real projects, from a certifiable prosthesis to a complete vehicle.
End to end
Real projectCarbon prosthesis: from CAD to test bench
Design, over 1,000 FEM simulations, a carbon-fiber prototype and lab tests to ISO 10328, through to the validation report.
Read the full case
Reverse engineering
Real projectA vehicle brought back to CAD and converted to electric
A 3D scan, rebuilt body surfaces and new components designed for the conversion from combustion to electric propulsion.
Read the full case
E-mobility
Real projectModular battery pack
Modular architecture for cylindrical cells: mechanical structure, plates and fixings designed for assembly, maintenance and scalability.
Read the full caseAll real projects: some from the founders’ published research, others from professional work, shown in anonymised form. Full confidentiality on the customer’s projects and data.
FAQ about design and FEM
From both. We can design from scratch based on the functional requirement, or develop and validate a drawing or component you already have.
Structural analysis (stresses, deformations, safety factors) and, where needed, thermal and fatigue. We give you a report in the technical dossier.
Both. We can stop at the validated design, or also handle the production of the special component, always with a single point of contact.
Yes. We build FDM and SLA 3D-printed prototypes to check clearances, assembly and shape before production, and we improve existing components for weight, strength, cost or manufacturability.
Yes. Absolute confidentiality on the customer’s projects, drawings and know-how. For us it is a baseline condition.
As an order of magnitude: the FEM verification of a single component is usually completed in one to two weeks; a full project, from requirement to finished part, takes one to three months depending on complexity. After an initial assessment we give you a defined lead time and price, before you commit.
A component to make lighter in carbon fiber?
We design and make composite components from start to finish: layup, molds, production with dedicated partners and material characterization.
Tell us about your project
Tell us about the component or assembly to develop. We’ll reply with the next steps.