Case Studies
Real-world examples of our engineering excellence in action
Client Success Stories
Explore how our engineering expertise has helped clients across various industries overcome challenges, improve performance, and achieve significant cost savings.
Lightweight Automotive Bracket Redesign
Challenge:
A German automotive supplier needed to reduce the weight of a critical structural bracket by at least 15% while maintaining structural integrity and keeping manufacturing costs competitive.
Solution:
Our team applied topology optimization and design for manufacturing principles to redesign the bracket. We conducted comprehensive FEA simulations to validate performance under various load conditions and collaborated with manufacturing engineers to ensure cost-effective production.
Results:
The redesigned bracket achieved an 18% weight reduction while improving structural performance by 7%. Manufacturing costs were reduced by 12% through optimized material usage and simplified production processes.
Aircraft Cooling System Optimization
Challenge:
A French aerospace company was experiencing overheating issues with electronic components in their aircraft systems, leading to reduced reliability and increased maintenance costs.
Solution:
We conducted thermal analysis using advanced CFD simulations to identify airflow bottlenecks and hot spots. Based on these findings, we redesigned the cooling channels and heat exchanger geometries, optimizing them for maximum efficiency within the tight space constraints.
Results:
The optimized cooling system reduced operating temperatures by 15°C, extending component lifespan by an estimated 40%. This resulted in reduced maintenance frequency and significantly improved system reliability.
Railway Bogie Component Reliability Improvement
Challenge:
A major European railway operator was experiencing frequent failures of a critical bogie component, leading to unplanned maintenance and costly operational disruptions.
Solution:
Our engineering team conducted failure analysis and root cause investigation, revealing stress concentration issues in the original design. We redesigned the component using advanced materials and optimized geometry, then validated the new design through extensive FEA simulations and accelerated life testing.
Results:
The redesigned component demonstrated a 300% improvement in fatigue life, extending maintenance intervals from 6 months to 2 years. This reduced maintenance costs by €1.2M annually and significantly improved operational reliability.
Manufacturing Process Optimization
Challenge:
An industrial equipment manufacturer was struggling with high scrap rates and quality issues in their production process, resulting in increased costs and delivery delays.
Solution:
Our team conducted a comprehensive analysis of the manufacturing workflow, identifying bottlenecks and quality risks. We redesigned critical process steps, implemented improved quality control measures, and developed custom fixtures to enhance consistency and repeatability.
Results:
The optimized manufacturing process reduced scrap rates by 62% and improved overall equipment effectiveness (OEE) by 27%. Production capacity increased by 35% without additional capital investment, and delivery times were reduced by 40%.
These case studies represent just a sample of the engineering challenges we've successfully addressed for our clients. Our approach combines technical expertise, creative problem-solving, and a deep understanding of industry-specific requirements.
Ready to discuss your engineering challenges?
Our Problem-Solving Methodology
We follow a structured approach to engineering challenges that ensures consistent results and client satisfaction.
Problem Definition
We work closely with clients to clearly define the challenge, objectives, and success criteria.
Analysis & Ideation
Our engineering team analyzes the problem from multiple angles and develops innovative solution concepts.
Solution Development
We refine and develop the most promising solutions, validating them through simulation and analysis.
Implementation & Validation
We support the implementation process and validate results against the defined success criteria.
Let's Solve Your Engineering Challenges
Contact us today to discuss how our expertise can help your business overcome technical challenges and achieve your goals with European-quality engineering at competitive prices.
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