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 higherefficiency, stability and product reliability, while reducing the need for costlyphysical 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 Internal Combustion Engines - H2ICE
We support the transition from fossil fuels to hydrogen-powered mobility by developing, simulating and validating hydrogen combustion engines with 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.
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.
Premium
CAD On-Demand
Designed for medium-sized projects with multiple parts or complete assemblies. Provides flexible development capacity and reliable planning security.
- 3 month duration
- Up to 10 individual parts or one medium-sized assembly
- Manufacturing drawings included
- 2 Revisions per task
- Access to manufacturing partners
- Assessment of flow and thermal optimization opportunities
- Effective monthly value: 3,250€
Typically equivalent to around 150 engineering hours. You benefit from clear deliverables instead of timesheets.
Premium
CFD On-Demand
Designed for medium-sized simulation projects, from variant comparisons to system validations. Provides flexible capacity to optimize flow guidance, cooling performance, or pressure loss.
- 3 month duration
- Includes 4–6 stationary simulations or up to 2 transient scenarios
- Benchmarking and variant comparison
- Detailed reports with optimization recommendations
- 2 Revisions per task
- Computationally intensive applications are not included
- Effective monthly value: 4,333€
Typically equivalent to around 150 engineering hours. You benefit from clear deliverables insteadof timesheets.