Design &

Development

Short Facts

  • Extensive expertise as a development service provider and general contractor
  • Design in Catia V5, Siemens NX, Pro-E, and Creo Parametric
  • decades of experience in automotive and motorsports development
    • Formula, GT, rally, and LMDH cars
    • time- and cost-efficient implementation
    • Extensive expertise in lightweight construction (GRP, NFK, and CFRP)

Your specialist for

Prototypes

Special-purpose vehicles

Small series

Motorsport

Development

Range of Services

Project planning

Goals & Milestones

Concept phase

Ideas & Concepts

Development

Design & Simulation

Prototyping

Testing & Certification

Mass production

Start of production

Supplier Management

Quality Planning

Risk Management

Validation & Approvals

Development

Entire vehicle

Development

Body-in-white

Rough modification

  • Optimized design for motorsports and small-batch production
  • Simulation throughout the development process (FEM, NVH, crash testing)
  • Integration of powertrains and chassis systems
  • Compliance with crash test requirements
  • Development of tolerance and assembly concepts
  • Production planning
  • Prototype development and support for production launch

Security cells / Roll cages

  • Concept & Package
  • Design in accordance with current regulations and specifications
  • Structural design
  • Production support
  • Prototype and Small-Batch Manufacturing
    with FIA and DMSB certification

Development

Exterior

Exterior Development

  • Component development based on design, aerodynamic, and structural data
  • Design, Construction, and Optimization of Attachments
  • Space optimization for certification and manufacturing
  • Integration of electrical, mechanical, and external peripheral components (lights, cameras, sensors)
  • Design of hinge, door, and opening mechanisms
  • Definition of component separations
  • Gap Clearance and Sealing Design
  • Assembly Design

Development

Suspension

Development

  • Comprehensive suspension development
  • Concept & Package
  • Designs suitable for manufacturing and assembly
  • Design of Axle Kinematics
  • Design of a spring-damper systems
  • Structural design
  • Improving driving efficiency

Testing

  • Construction of prototypes and test vehicles
  • Use of appropriate measurement technology
  • Determination of operational loads
  • Endurance run
  • Suspension tuning
    • Improving driving efficiency
    • Improving steering performance and dynamics

Driving dynamics

Ride comfort

Driving Safety

Development

hydraulic vehicle systems

System Development

  • Selection and Design of System Components
  • Development of the System Architecture
  • Vehicle system integration
  • Development and Construction of Test Benches
  • Conducting functional tests
  • References
    • F1 Clutch
    • Integration of hydraulic suspension
    • hydraulic stabilizer
    • active aerodynamics

hydraulic racing steering gearboxes

> 1,500 steering mechanisms

Development

  • Optimization of Production Steering Gears
  • End-to-end development
    • Housing design (machined or die-cast)
    • Performance and Package Optimization
    • Development of a Sealing Concept
    • customized and optimized valves
    • modular solution with proprietary gear components

Prototype and Production Manufacturing

  • efficient assembly process
  • In-house production of assembly tools
  • digital assembly documentation
  • Installation instructions for each steering gear
  • highly qualified professionals
  • Hydraulic balancing of the steering valve on the test bench

hydraulic steering test bench

  • 100% inspection of all steering gears before shipping
  • Modern and versatile steering test bench
  • High-quality measurement technology with digital recording (measurement of various operating parameters such as pressure, temperature, force, displacement, and torque)
  • Testing at different temperatures and oil flow rates
  • Measurement of supply and chamber pressures
  • dynamic wear testing
  • static high-load tests

Full-service offering

years of expertise

highest quality standards

Development

E-E

Systems Engineering - Wiring Harness Modification

  • Function and Application Development
  • Development and modification of on-board systems
  • E-E System Development
  • E-E System Integration
  • Creation of system and wiring diagrams
  • Creation of layout models
  • Change and Variant Management
  • Interface Management
  • Prototype and small-batch production
  • Commissioning and Functional Testing

Measurement Technology Testing

  • extensive experience in motorsports and prototype development
  • Setup of test benches
  • Vehicle equipment with measurement technology
  • Functional testing
  • Endurance Running Support
  • Analysis and Documentation

Development

References

Motorsport

Prototypes and special vehicles

Small series

2018-2020

BMW

M2 CS Racing

mini-electric-pacesetter-inspired-by-jcw

Mini

Electric Pacesetter

2026

Escalador

Experience freedom

screenshot2018-07-2407.33.13

Porsche

GT3_R

2019

Porsche 911

Altitude Edith

Toyota-Supra-A90-Final-Edition-2869-6391x3595-a220d2efe8ac6245

Toyota

Supra A90 Final-Edition

2010-2012

Hispania

Racing F1

2017

Holzer

Rally R5 Prototype

2013-2015

Lotus

Bike C01

Project planning

  • cross-departmental requirements management
  • Goal definition and concept determination
  • Schedule and milestone planning
  • Resource and budget planning
  • Quality & Risk Management
  • Procurement and Supplier Integration

Concept phase

  • Technical market analysis and needs assessment
  • Product Definition and Specification Development
  • Technical design validation
  • Vehicle Architecture Design
  • Installation Space and Ergonomics Analysis
  • Concept analysis regarding type approval
  • Business Case and Concept Approval

Development – Design & Simulation

  • Design
    • Selection of Materials
    • Ensuring functionality
    • Kinematics design
    • Development of Assemblies & Components
    • Tool and Fixture Manufacturing
  • Validation & Simulation
    • FEM
      • Structural and Stiffness Analysis
      • Fatigue Analysis of the Car Body
      • Eigenvalue and Frequency Response Analysis
      • Analysis of thermal loads
    • Crash
      • Component and vehicle levels
      • all relevant crash scenarios (frontal, side, and rear impacts according to ECE, FMVSS, and EuroNCAP)
      • Vulnerability identification
      • Drawing on our in-house expertise and a strategic network of partners, we offer you cutting-edge technologies and future-proof solutions for first-class results

Prototyping – Testing – Certification

  • Concept Prototyping & Virtual Mock-Up (Digital PEP)
  • Prototype development
    • Test rig (engine mount)
    • Development and Construction of Test Benches
    • Design & Ergonomics Prototypes (Physical Mock-Up)
    • Endurance vehicles
    • Feedback of findings into the development process
    • Pre-production (production validation)
  • Trial Management
    • Planning and conducting all tests
    • Preparation for and support during the homologation process

Small-batch production

  • Preparation of small batches for assembly line production
  • Processes optimized for prototyping and small-batch production
  • Production Process and Product Release (PPF)
  • Start of Production (SOP) & Ramp-up
  • Production Control
  • Change Management
  • Supplier Management
  • Quality Assurance