David L.

Felsaris GmbH is a German mechanical engineering firm specializing in CFD simulation, combustion engine development, cooling systems, vehicle aerodynamics and engineering data mining. We combine 0D/1D simulation, 3D CFD, testing and measurement data to support virtual product development, performance optimization and technical decision-making. Based in Mannheim, Germany, we support automotive and motorsport companies, engine developers, low-volume vehicle manufacturers and engineering teams requiring additional simulation capacity. Our flow and thermal engineering expertise also extends to aerospace, energy and industrial applications. OUR ENGINEERING SERVICES ➤ CFD Simulation | Fluid Flow & Heat Transfer Steady and transient 3D CFD analysis of internal and external flows, pressure losses, heat transfer and thermal loads. Applications include intake and exhaust systems, turbomachinery, cooling systems and industrial flow components. We deliver documented simulation setups, evaluate flow distribution and thermal behavior, and compare design variants. Methods include RANS, URANS, DES and conjugate heat transfer, selected according to the engineering question and available validation data. ➤ Combustion Engines | GT-SUITE & GT-POWER Complete engine modeling for full-load performance, operating maps and load transients. Services include model development, reverse engineering, calibration, turbo matching, air and exhaust path analysis, combustion modeling and test bench validation. Performance studies account for constraints such as lambda, boost pressure, exhaust temperature, emissions, cooling capacity and existing hardware. Hydrogen combustion engines (H₂ICE), alternative fuels, reaction kinetics and water injection are specialist areas. ➤ Cooling Systems | System Modeling & Thermal Analysis 1D models of coolant, oil and charge-air circuits, combined with 3D CFD for local flow and heat transfer. We investigate radiator sizing, pumps, pressure losses, heat balances, cooling air mass flow, engine compartment flow and thermal hot spots. Applications include combustion engines, electric motors, inverters, batteries and gearboxes. Transient analyses help assess thermal margins under changing operating conditions. ➤ Aerodynamics | Complete Vehicles & Components CFD analysis of drag, lift, downforce, side forces and aerodynamic moments. We investigate wings, underbodies, diffusers, wakes and vortex structures, including the effects of ride height and yaw angle. A particular focus is the interaction between aerodynamics and cooling: inlet and outlet design, radiator airflow, heat rejection, drag and aerodynamic balance. Services include wind tunnel correlation, simulation-based optimization and pressure-load data for structural analysis. ➤ Data Mining | Engineering Data Analysis & Predictive Models Modular data pipelines for test bench, vehicle, wind tunnel and simulation data. We handle data import, signal mapping, plausibility checks, segmentation and automated calculation of engineering metrics. Methods include Design of Experiments, regression, correlations, sensitivity analysis, machine learning and surrogate modeling. Measurement data can be enriched with calculated quantities from 0D, 1D and 3D models. Reusable Python and MATLAB modules provide transparent, repeatable evaluation workflows. CONNECTED ENGINEERING Engine performance, cooling demand and aerodynamics influence one another. We connect these disciplines through consistent boundary conditions, heat balances and measurement data. Individual simulation models and analysis modules can also be delivered as standalone work packages. TYPICAL DELIVERABLES • Reproducible CFD setups and documented boundary conditions • Calibrated 1D engine and cooling system models • Performance maps, heat balances and design comparisons • Aerodynamic coefficients, pressure distributions and load data • Automated data evaluation workflows and validated predictive models • Technical reports with assumptions, limitations and engineering recommendations ENGINEERING EXPERIENCE The engineering background behind Felsaris includes project experience with HWA AG, Audi Sport DTM, Porsche Motorsport, KEYOU, KIT IFKM, IHI Charging Systems and BorgWarner Turbo Systems, covering CFD, engine development, hydrogen combustion, cooling, aerodynamics, turbomachinery and measurement data analysis. CORE TOOLCHAIN STAR-CCM+ | ANSYS CFX | CONVERGE CFD | OpenFOAM | GT-SUITE / GT-POWER | Python / Cantera | MATLAB / Simulink We provide defined engineering packages and ongoing development support, with agreed objectives, deliverables and documented results. For German R&D projects, we also offer funding advisory and technical application preparation for Forschungszulage and ZIM. Share the technical objective, available geometry or measurement data and required timeline through Upwork to discuss the project scope.