Product Development for SMEs: AI, CAD & CFD by Felsaris

Felsaris Behind the Scenes: Modern Product Development for SMEs

While established corporations can rely on extensive R&D departments, small and medium-sized companies face the challenge of delivering innovative product development with limited resources. Felsaris closes exactly this gap by combining modern engineering expertise with AI-supported development processes-successfully bringing SMEs and high-tech together.

Who We Are: An Engineering Team with a Clear Mission

The Felsaris team combines over 15 years of experience in computer-aided development with a clear focus: making complex engineering tasks understandable and turning technical solutions into reality with ease. Our Managing Director David Leimann, M.Sc. in Mechanical Engineering from the Karlsruhe Institute of Technology (KIT), acts as the technology driver and ensures precise and efficient project execution through his deep expertise.
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The team is strengthened by Sabrina-Catherina Leimann in communication and administration, while our “good mood manager” Mila ensures that the atmosphere stays positive even during intense project phases. This personal touch sets us apart from large engineering providers—we are your innovation team with a face and a clear mission.

Our Way of Working: Trust, Transparency, and Partnership

Trust as the Foundation

Trust is the benchmark we use for every decision. Honesty, transparency, and responsibility are our moral compass for every technical and business decision. We protect our clients from bad investments by openly disclosing all facts, presenting realistic benefits, and clearly identifying risks. This approach builds trust, minimizes investment risks, and ensures our work is designed for lasting impact.

Excellent Service with a Long-Term View

We act proactively to truly relieve our clients and drive projects forward successfully. We don’t just respond to requests—we identify opportunities and risks early, optimize processes, and use technologies to preserve our clients’ resources. In this way, we become the enabler that turns ideas into impact and ensures projects reach their goals.

Growing Together

We measure our success by the strategic value we create for our clients, with the goal of building lasting growth. We do not view growth as a short-term target, but as a partnership based on responsibility. Every recommendation is based on transparency, technical integrity, and strategic foresight. This is how we create solutions that not only work, but also secure long-term competitive advantages for our clients.

Modern Product Development: From Idea to Series-Ready Product

Product development at Felsaris follows a structured yet agile process that combines innovative engineering with state-of-the-art digital tools. Unlike traditional development approaches, we rely on AI-supported methods that shorten development cycles while increasing quality.

CAD Design: Precision from the First Draft

Our CAD design starts as early as the concept phase with high-precision 3D models for components and assemblies. The focus is on maximum functionality, optimal manufacturability, and efficient development processes. Parametric modeling allows us to create variants quickly and transfer changes seamlessly into all project phases.

Simulation and Optimization: Virtual Before Physical

With 3D CFD flow optimization, we make the invisible visible. High-resolution flow and thermal simulations reveal optimization potential, pressure losses, hotspots, and flow disturbances long before physical prototypes are built. These virtual validations not only reduce development costs but also significantly accelerate the entire development process.

Rapid Prototyping: From Idea to Prototype in Record Time

Through 3D scanning, reverse engineering, and industrial 3D printing, we deliver functional prototypes quickly, precisely, and perfectly suited for validation and further development. Through our network of verified partners, we offer both conventional manufacturing methods such as turning and 5-axis milling and additive manufacturing using FDM and resin-based SLA or DLP processes.

Why We Successfully Bring SMEs and High-Tech Together

Agility Instead of Bureaucracy

Compared to large engineering providers, we work leaner, more agile, and significantly faster. With our approach, we can often deliver projects up to 50% faster—without compromising precision or quality. Direct client contact and a flexible way of working lead to shorter project timelines and individually tailored results.

Technology Transfer from High-Tech Industries

Our cross-industry expertise in automotive, aerospace, energy, and mechanical engineering enables us to transfer proven methods from high-tech sectors into customized development projects. From scientific research and motorsport to pre-series development, we have successfully implemented numerous complex projects.

AI Integration for SMEs

For particularly demanding tasks, we use state-of-the-art correlation models, machine learning, and artificial intelligence. We integrate AI in a targeted way to accelerate development cycles and increase simulation accuracy. Surrogate models replace classic trial-and-error approaches and enable fast, data-driven predictions.

Hydrogen Technology: The Catalyst for Tomorrow’s Powertrains

A special focus of our work is the development of hydrogen engines (H₂ICE). With deep expertise in boosting systems, injection technology, simulation, and emissions control, we convert combustion engines for hydrogen operation. Using 3D scans and reverse engineering, we fully capture existing engines and develop new hydrogen-capable components based on that data.
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These are designed using advanced CAD and CFD simulations and then validated in real test bench experiments. This results in powerful hydrogen engines with zero CO₂ emissions that are ready for use in the shortest possible time. Especially for SMEs in the automotive sector, this opens up entirely new market opportunities in sustainable mobility.

Innovation and Funding Consulting: ZIM as a Turbo for R&D

Innovation does not happen by chance. That’s why we support our clients not only technically but also strategically in innovation development. In structured innovation workshops, we capture strengths, apply proven creativity methods, and analyze market potential to shape future-oriented projects.
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Our expertise in the Central Innovation Programme for SMEs (ZIM) is particularly valuable. We support the entire ZIM application process—from validating the idea to final submission. With technical expertise and clear communication, we maximize approval chances and secure funding of up to €690,000 for innovation projects.

On-Demand Services: Flexible Capacity for Fast Results

Not every company needs continuous engineering capacity. That’s why our CAD and CFD on-demand packages offer flexible solutions for short-term projects. Companies can decide whether they need support for just a few weeks or several months. Since license costs for our software solutions are already included, there are no additional fixed costs.
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These packages are designed to match the needs of start-ups, SMEs, and complex development projects. Clients benefit from predictable costs, flexible usage, and a high quality standard—without long-term commitment.

Data-Driven Development: AI as a Competitive Advantage

Traditional product development usually follows the “One-Factor-at-a-Time” principle, with limited interaction analysis and high dependency on individual expert knowledge. Our data-driven approach uses machine-learning-based surrogate models, statistical DoE distributions, and GPU-accelerated simulation platforms to significantly accelerate the design phase.
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Through AI integration, we enable objective, fast variant evaluation that leads to global rather than local optima. This is particularly relevant for SMEs to counter skills shortages, time pressure, and cost pressure. Our methods allow deeper exploration of the design space while reducing simulation effort at the same time.

Conclusion: Your Partner for Future-Proof Product Development

Felsaris combines the best of two worlds: the agility and customer proximity of a mid-sized company with the technological expertise from high-tech industries. Through our partnership-driven way of working, the use of state-of-the-art AI-supported development methods, and our comprehensive funding consulting, we give small and medium-sized companies access to technologies that would otherwise be reserved for large corporations.
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Whether CAD design, CFD simulation, hydrogen technology, or innovation consulting—we support you from the first idea to the series-ready product. Contact us now and let’s realize your next innovation together.

Frequently Asked Questions About Product Development at Felsaris

What sets Felsaris apart from other engineering service providers?

We combine the agility of a mid-sized company with state-of-the-art AI-supported technology. Through direct client contact, flexible working methods, and the use of machine learning, we can deliver projects up to 50% faster than large engineering providers—without compromising quality or precision.

What does a typical product development process at Felsaris look like?

We start with a consultation, capture your requirements, and define clear technical goals. From the first CAD draft through CFD simulations to a functional prototype, we contribute our know-how in design, simulation, and optimization. AI-supported methods accelerate the entire development process.

Can small companies also benefit from professional CFD simulation?

Yes. Through our on-demand services, we make professional simulations accessible even for smaller budgets. Since license costs are already included and we offer flexible durations, there are no high fixed costs. This gives you high-quality simulation results without long-term investments in software and hardware.

What role does AI play in modern product development?

AI makes it possible to significantly shorten development cycles while increasing quality. With machine-learning-based surrogate models, we can explore the design space more efficiently, find optimal solutions faster, and develop predictive models for future design decisions.

Does Felsaris also support the financing of innovation projects?

Yes. We specialize in ZIM funding consulting and support you from the innovation workshop to successful application submission. With our expertise, we maximize your approval chances and can secure funding of up to €690,000 for your innovation project. The workshop itself is already eligible for 50–80% funding.