Looking back: 30 projects from 30 years

When it started, a small team of engineers computed the first orders for two major automakers in the company founder's living room. CAE was still in its infancy as a development method. OEMs increasingly adopted the method as computer capacities increased and software improved. In the meantime, TECOSIM grew from a two-man operation in 1992 to become what is now a renowned engineering company with some 550 employees. TECOSIM takes 30 exemplary client projects from its 30 years to look back on its company history.

2022: Hull University - lifespan of offshore wind turbines

TECOSIM works together with the University of Hull in the UK on a study on the lifespan of offshore wind turbines. The project begins in August 2021 and ends in July 2022. The research focuses primarily on what are known as turbine monopiles. These are one of the turbine components most susceptible to fatigue since they are exposed to stress loads caused by waves, tides and weather conditions.

2020: Bäro GmbH - simulating aerosol spread

Minimising the risk of infection. When the coronavirus pandemic breaks out, TECOSIM uses CFD simulation to develop a method to contain the spread of fungi, viruses and bacteria. As part of a cooperative partnership with BÄRO, the experts simulate a classroom and compare aerosol spread with a window open to spread when filter systems are fitted. The team then performs a number of optimisation loops.

2019: Bosch E-Bike Systems - growth market in e-bikes

The market for e-bikes is expanding at a frenetic pace. Vehicle quality requirements are also growing as supply increases in variety and breadth. TECOSIM has been working for the sector since 2019. The first project involves simulating an out-of-the-saddle test.

TECOSIM: Virtuelle Crashoptimierung für e.GO Life

2017: E-Go-Life - virtual crash safety optimisation

The e.Go Life is a small electrically powered car developed by Aachen-based e.Go Mobile AG (now Next e.Go Mobile). TECOSIM assists e.GO by using simulation and calculation to develop a comparatively lightweight vehicle body which complies with all statutory safety requirements.

2017: Rehau - safe and extremely stable

State-of-the-art composites are capturing the automotive engineering sector. REHAU develops production procedures which continually increase the use of these lightweight materials. TECOSIM assists in this process by calculating and simulating a variety of material properties.

2016: Concepts for tomorrow today – ZF Advanced Urban Vehicle

Extremely versatile, locally emission-free and networked with drivers and the environment, ZF presents the potential that intelligent networking of individual chassis, propulsion and driver systems brings in its Advanced Urban Vehicle. TECOSIM assists in the project by determining different load cases and dynamic rigidities in the axle sections and battery installation locations.

2015: Progress through safety AUDI Q7

Safety is also given top priority in the development of the new AUDI Q7 and its derivatives. TECOSIM assists the client in meeting this requirement with FE calculations for different material thickness widths and simulation of the complex joining technology.

2014: Vision and reality unified BMW i8

The desire to produce a completely new vehicle concept becomes a reality in the BMW i8. TECOSIM assists in development right from the outset with the focus on occupant safety. The CAE specialists study different crash scenarios with pole impact and barriers, optimising restraint systems and side structures based on their findings.

2013: Post haste quiet, safe delivery

Streetscooter GmbH develops innovative, electrically driven van for urban delivery services. TECOSIM assists in developing the crash-optimised car body for a safe battery installation position. The CAE specialists calculate and simulate different crash scenarios and structural rigidity for the used materials.

2013: Hitting the right noteEnzenauer Piano- und Flügelmanufaktur GmbH

TECOSIM calculates a new cast frame – the sound element and core component in a grand piano – for the first time for Enzenauer Piano und Flügelmanufaktur. The computer-based optimisation of the design and soundboard enable TECOSIM to create a significantly improved experience of sound.

2013: Solutions for automotive efficiency – ThyssenKrupp InCar®plus
The ThyssenKrupp InCar®plus project promises weight reductions of up to 50 percent while complying with customary crash and safety test requirements. TECOSIM assists in the functional design of over 40 new components and solutions in the electric motor and steering system environment and in creating a cost-effective, crash-optimised lightweight material mix.

2012: Consolidating integral efficiency  JUWI solar system frame

TECOSIM calculates new clamping system to mount solar panels for solar system pioneer Juwi in just four weeks. Reducing the amount of material at points subject to less stress decreases overall weight by up to 39 percent.

2012: Olympian expertise  – Olympic torch

The specification that the London Organising Committee of the Olympic and Paralympic Games (LOCOG) gave to TECOSIM is short and very clear: the torch must not go out. To meet these requirements, the engineers first run a computational fluid dynamics and combustion simulation to calculate the behaviour of the torch at temperatures between -5 ºC and +40 ºC as well as at wind speeds of up to 56 km/h and gusts of up to 80 km/h. Fall scenarios (drop tests) from heights of up to three metres are also simulated on the computer. Additional tests in the wind tunnel and real-life drop trials with prototypes confirm the results from the computations. The development engineers also analyse different properties to identify suitable materials.

2012: More kick to the horse – AMG Mercedes SLS ED

Four electric motors generate an output of 552 kW (751 hp) and a torque of 1,000 Nm for the Mercedes AMG SLS ED, an electric-drive model. TECOSIM provides its expertise in calculation and simulation for the newly designed axle units.

2011: Firm hold for every size Schott telescope mirror

A specialist in telescope mirrors, Schott commissions TECOSIM to calculate and simulate the structure for a rotating frame supporting an eight-ton telescope mirror.

2011: Help in returning home safely Glider turbine

Glider turbines specially designed to assist in returning to base are increasing in popularity. TECOSIM simulates different model scenarios for a newly developed turbine type as part of a research project. The aim is to guarantee that the pilot is protected against components projected out in the event of mechanical destruction.

2009: Beefed up Lamborghini Huracán

The extremely robust, yet super-light hybrid chassis for the Lamborghini Huracán consists of a carbon-reinforced composite carbon structure with aluminium elements. TECOSIM tests and validates this complex chassis element, also referred to as a space frame, with regard to different crash regulations.

2008: Steaming ahead with a comfortable environment Bombardier

Railway customers have a clear idea of what a comfortable travel climate is. Aero- and thermo-dynamic simulations and calculations allow TECOSIM to achieve even distribution within a limited installation space during the development of a new railway carriage.

2008: An extra dose of security – AUDI A8 L Security

The Audi A8 impressively demonstrates what is technically feasible in terms of safety. TECOSIM is responsible for re-calculating crash properties. This proves to be challenging. The vehicle features a drastically modified vehicle body and driving performance due to additional material modifications and increased gross load weight.

2006: True pioneering work – Mitsubishi i-MiEV

TECOSIM applies its know-how to electric mobility. The CAE engineers assist in crash safety and battery design and are responsible for adjustment simulation during development of the Mitsubishi i-MiEV.

2005: Eager for safety BMW 7 series

TECOSIM assists in developing a new model range from an early stage. This comprehensive project focuses on calculating the best possible occupant safety for the world's most demanding frontal crash protection.

2004: A common objective – Fiat Punto

General Motors and Fiat cooperate on the development of a new small car series and devise a joint platform. TECOSIM handles crash simulation and virtual mapping of audible noise, also felt as vibration (NVH), and also qualifies as an expert partner in the premium simulation league.

2002: The whole picture – Opel Zafira

This TECOSIM project not only achieves five stars in customary crash tests, but also sets a new course in terms of strategy. The project focuses on integral product development for the first time. TECOSIM sets the course for a new strategic orientation as a virtual developer for complete vehicles.

2001: Ready to open – VW New Beetle Cabrio

Volkswagen is one of the first automotive manufacturers to bring a vehicle in a retro design onto the market. TECOSIM assists in complete vehicle development for this Cabriolet derivative. The focus lies on calculating crash and NVH properties.

1999: Entry into the premier league Porsche Boxster

Almost six years after its first order, TECOSIM contributes its calculation expertise in the development of the new mid-engined sports car. The CAE engineers calculate the modification to the Porsche 911 front section for the model series and successfully map the required crash load cases. TECOSIM thus extends its client base to include premium and sports car manufacturers.

1998: Moment of glory for virtual development – Opel Corsa

TECOSIM handles complete crash calculation for the new Opel Corsa. This includes mapping of load cases in the front, rear and side sections of a vehicle for the first time. The calculations and subsequent validations also impress the clients. Not least, because the Corsa almost achieves five stars in the Euro NCAP test, the first small car ever to do so.

1996: Pedestrian safety crash load – Ford Mondeo

TECOSIM takes global requirements into account to calculate the crash loads in the front section of the vehicle for newly mandatory pedestrian safety systems, thus expanding its range of services.

1995: A door openerOpel Zafira

Opel places its trust in TECOSIM once again for the development of its successful compact MPV. The CAE engineers calculate the different crash load cases and deliver valid results to Porsche Engineering. The company is responsible for complete vehicle development and is impressed by the quality of TECOSIM's work. Word spreads quickly.

1994: The second client Opel Omega

General Motors needs to respond to changes in crash regulations for the American market within a short period of time. TECOSIM receives the order to provide virtual calculation for Opel Omega – a vehicle derivative for the European market.

1993: Start of a success story Ford Fiesta

The use of computer-aided engineering is new, largely unexplored terrain for vehicle developers, even at Ford, a field which developers are sceptical towards. Four employees use just three computers (HP Unique Workstations 735) to calculate different crash load cases in a virtual environment and thus complete TECOSIM's first order very much to Ford's satisfaction.