Your Partner for Developing
Tomorrow’s Products

With our competence, passion, and exclusive expertise, we work together with you to develop your next company’s innovations.

Our Services

We offer you a comprehensive service portfolio for the redefinition and optimization of your products and components:
starting from the idea development to the finished prototype. Everything from one source!

ANALYSIS & CONCEPT

Taking you from Idea to Concept

We work with you to develop innovative ideas for your products and apply them to deliver concepts specifically tailored to your application, using modern approaches such as 3D printing and optimization.

Carving out the right path

We carry out an in-depth analysis of your application together with you. Based on geometry, material, and load, we analyze the optimization potential of your components. At this stage our interdisciplinary team takes your industry-specific requirements into account.

Finding the right material

As experts in materials science, we can advise you in the selection of the most suitable materials and processes for your specific application. We take the full range of materials into account, including metals, plastics, ceramics, and composites.

  • Concept Development
  • Feasibility Studies
  • Materials & Process Selection
  • Materials Testing

PRODUCT DEVELOPMENT

Modern Technologies for Best Results

We deliver the highest performance for your specific application, using our proven expertise to combine established methods with modern technologies, such as simulation-driven parametric design, as well as 3D printing.

Software-supported optimization and human intuition

We use the latest professional software for component optimization, in addition to our vast experience and unique knowledge base in biomimetic engineering. We also make use of exclusive research results, which we implement using our in-house optimization software.

We don’t leave anything to chance

For final validation of the optimized design, every component we build is subject to in-depth FE analysis and evaluation by our trained engineering staff.

  • Biomimetic Lightweight Design
  • Functionally Graded Cellular Structures
  • Development of automated CAD-workflows
  • Simulation & Design Validation
  • Reverse & Re-Engineering

REALIZATION

Your Idea comes to Life

We support you all the way through to the production of your optimized component, using either or in-house prototyping capabilities, or helping you to select a suitable partner for the serial production.

Prototyping

Nothing gives a clearer impression of a design than a tangible prototype. We offer you to take over the task of producing your functional test samples and prototypes using our in-house resources and extensive partner network of production and finishing service providers.

Ready for Serial Production

We are also there for you beyond the prototyping stage to help your innovation make the leap into serial production. At the same time, we keep a close eye on the efficiency and feasibility of the project right from the beginning..

  • Prototyping
  • Small-scale Production
  • Economic Profitability Analysis
  • Component Testing

Taking Your Project to Success!

We believe that the key to success are effective cooperation and close communication with you while we support your project.

Our development projects typically include the following stages:

INITIALIZATION

As a first step, we discuss and analyze your project by way of a non-binding initial meeting, free of charge.

SPECIFICATION

Following up, we work with you to specify and document the objectives, constraints and requirements of your project.

CONCEPTION

On that basis, we assess the available options and develop the best concept for your application.

CONSTRUCTION

We now combine our versatile CAD and FEA tools to efficiently construct and optimize your product.

VALIDATION

The final validation of the optimized design is performed via professional FEA software. If required, we use component testing to complement our findings.

FABRICATION

We are available to assist in the fabrication of prototypes and small batches of your optimized product.

INITIALIZATION

As a first step, we discuss and analyze your project by way of a non-binding initial meeting, free of charge.

SPECIFICATION

Following up, we work with you to specify and document the objectives, constraints and requirements of your project.

CONCEPTION

On that basis, we assess the available options and develop the best concept for your application.

CONSTRUCTION

We now combine our versatile CAD and FEA tools to efficiently construct and optimize your product.

VALIDATION

The final validation of the optimized design is performed via professional FEA software. If required, we use component testing to complement our findings.

FABRICATION

We are available to assist in the fabrication of prototypes and small batches of your optimized product.

Biomimetic Engineering

Nature is an endless source of inspiration for designing tomorrow’s products.

For example, huge weight savings in technical constructions can be achieved by imitating the growth processes of bones. Biomimetic engineering not only allows highly efficient lightweight construction, but also the provision and integration of special functions in technical products for a multitude of application fields and sectors.

We are specialized in this type of biomimetic design.

TOPOLOGY OPTIMIZATION

We optimize the topology of your component with our specific software tools, using a number of different methods. The key principle of all these methods is to imitate the growth processes of bones, using local reinforcement and bracing where required, and minimizing the weight where possible. This results in a component that is optimized for your specific load cases.

Depending on your application, we can achieve optimized component rigidity in compliance with a pre-defined weight constraint, or we can minimize the component weight on the basis of a given set of mechanical constraints, such as maximum deflection and minimum safety factor.

We have comprehensive expertise and validated experience with these methods and can offer you a broad range of services in the topological optimization of your components:

Optimization for several load cases and scenarios

Calculation with isotropic, orthotropic and also viscoelastic materials (metals and plastics)

Optimization of demoldably geometries for manufacturing by injection moulding, pressure casting or milling

Combination of topology optimization and interior lightweight structures

Design evaluation using linear and non-linear FE analyses

CELLULAR STRUKTURES

Naturally inspired cellular structures such as honeycombs, foams and micro-lattices offer unique properties and possibilities for integrating specific functions into your products.

We use our broad database of fully characterized cellular structures which we can adapt and functionally grade to meet the requirements of your specific application. We also offer bespoke development of new components and structures which are specifically tailored to your requirements.

We have the required expertise and tools to model, optimize and simulate even your most complex mechanical and functional cellular structures.

Functionally graded structures optimized for the specific application

Highly efficient lightweight and cooling structures

Development of special functional structures (e.g. specific flexibility/rigidity adjustments)

Auxetic honeycombs and lattice structures

Complex slot and lock structures

Design evaluation using linear and non-linear FE analyses

GENERATIVE DESIGN

With generative design, customized products can be quickly executed by automating constructions according to variable geometric and functional requirements.

Digital product development is our core business. Software development and engineering expertise go hand in hand in our company. It is a powerful combination that enables us to develop generative CAE workflows for the time and cost-efficient construction of customized components and products. In the process, we also deploy special evolutionary algorithms that iteratively optimize a construction based on specific input data and target parameters.

Generative design is ideal for the serial production of customized products, such as patient-specific orthoses, implants, inserts, customer-specific sporting goods and everyday products, as well as customized machine parts.

Development of complex CAE workflows for product and component customization

Automated design of entire assemblies according to variable input data

Working in parametric CAD formats

TOPOLOGY OPTIMIZATION

We optimize the topology of your component with our specific software tools, using a number of different methods. The key principle of all these methods is to imitate the growth processes of bones, using local reinforcement and bracing where required, and minimizing the weight where possible.

Optimization Workflow

Definition of the geometry, constraints and load cases

Simulation-driven calculation of an optimized component design

CAD-based construction of the optimized component design using PolyNURBS

FE Analysis to validate the optimized design

The result is the final, optimized component ready for fabrication

Depending on your application, we can achieve optimized component rigidity in compliance with a pre-defined weight constraint, or we can minimize the component weight on the basis of a given set of mechanical constraints, such as maximum deflection and minimum safety factor.

We have comprehensive expertise and validated experience with these methods and can offer you a broad range of services in the topological optimization of your components:

  • Optimization for several load cases and scenarios
  • Calculation with isotropic, orthotropic and also viscoelastic materials (metals and plastics)
  • Optimization of demoldably geometries for manufacturing by injection moulding, pressure casting or milling
  • Combination of topology optimization and interior lightweight structures
  • Design evaluation using linear and non-linear FE analyses

CELLULAR STRUCTURES

Naturally inspired cellular structures such as honeycombs, foams and micro-lattices offer unique properties and possibilities for integrating specific functions into your products.

 

Broad Range of Structures

Funktionally-graded Honeycomb Structure.

We use our broad database of fully characterized cellular structures which we can adapt and functionally grade to meet the requirements of your specific application. We also offer bespoke development of new components and structures which are specifically tailored to your requirements.

We have the required expertise and tools to model, optimize and simulate even your most complex mechanical and functional cellular structures.

  • Functionally graded structures optimized for the specific application
  • Highly efficient lightweight and cooling structures
  • Development of special functional structures (e.g. specific flexibility/rigidity adjustments)
  • Auxetic honeycombs and lattice structures
  • Complex slot and lock structures
  • Design evaluation using linear and non-linear FE analyses

GENERATIVE DESIGN

With generative design, customized products can be quickly executed by automating constructions according to variable geometric and functional requirements.

Example

The component design is calculated according to the input parameters and predefined function.

An automated CAE workflow with special algorithms is the key feature of generative design.

It allows customized solutions to be developed and optimized to their precise requirements and needs.

Digital product development is our core business. Software development and engineering expertise go hand in hand in our company. It is a powerful combination that enables us to develop generative CAE workflows for the time and cost-efficient construction of customized components and products. In the process, we also deploy special evolutionary algorithms that iteratively optimize a construction based on specific input data and target parameters.

Generative design is ideal for the serial production of customized products, such as patient-specific orthoses, implants, inserts, customer-specific sporting goods and everyday products, as well as customized machine parts.

  • Development of complex CAE workflows for product and component customization
  • Automated design of entire assemblies according to variable input data
  • Working in parametric CAD formats

Biomimetic engineering offers enormous potential, both for 3D printing applications with its high degree of design flexibility, but also for components produced using traditional manufacturing methods, such as die casting or injection molding. We have access to a wide pool of established and in-house methods and software tools. This, along with our many years of experience, makes us uniquely qualified to optimize your products and components.

Industry Sectors

Our innovative services offer added value for a wide range of sectors and applications.

AEROSPACE

AUTOMOTIVE

MEDICAL TECHNOLOGY

MECHANICAL ENGINEERING

RAIL

ART & ARCHITECTURE

Lightweight design and structural optimization are in demand both for large products in heavy industry as well as for filigree structures in space, aviation and medical technology. Exceptionally efficient biomimetic solutions can also bring benefits for various mechanical engineering applications as well as for toolings and mechanical devices. Weight savings are a top priority in automotive, aircraft and space construction. At the same time, safety aspects are a key concern in the construction of elastic and/or rigid structures. In addition to their practical benefits, biomimetic structures and design concepts also offer an aesthetic value that is ideal for use in e.g. architecture or sporting goods.

This is what characterizes our way of working

INNOVATIVE

Our qualified and dedicated team supports you with new ideas and exclusive technologies for your products.

RELIABLE

Reliability and punctuality are always important to us. At the same time, our focus is on the quality of our work and your satisfaction!

IN LINE WITH REQUIREMENTS

Optimization is always a compromise between time, costs, and target criteria. Together with you, we find the perfect balance and develop an optimal solution for you, taking the existing requirements into account.

EFFICIENT

We combine the latest software and methods with our extensive experience and knowledge. This allows us to pursue the development of your product innovations with speed and efficiency.

References

3D-Printed bi-propellant Thruster Injector

SPACE

In cooperation with TRUMPF Laser- und Systemtechnik GmbH and the University of Stuttgart Institute of Space Systems, an optimized thruster injector for a small-scale satellite was developed that utilized the advantages of 3D printing. Biomimetic lightweight design and functional integration for fuel feeding and vibration damping were combined in the construction. After successfully passing the test phase, the component will be deployed in space.

Weight saving: 83 % (compared to the reference design)

Material: 718-A LMF (Nickel-base alloy, comparable to INCONEL 718)

Fabrication: LASER METAL FUSION

Cooperation Partners:

Biomimetic Chair Carrier

DESIGN & ARCHITECTURE

As part of a concept study commissioned by the company SEDUS Stoll, CellCore developed a biomimetic design concept for a chair carrier that combines load-optimized design and functionally graded honeycomb structures. The biomimetic construction, designed for metallic 3D printing, achieves a weight reduction of over 240 g in comparison with the current die-cast design.  Although the printed prototype in aluminum is too expensive to be implemented in serial production at the moment, it demonstrated that with increasing productivity of 3D printing technologies in the future new kinds of aesthetic and functional designs will find their application in the consumer industry. Furthermore, the company is using the optimized construction as a source of inspiration for future, conventionally manufactured product series.

Weight saving: 21 %  (compared to reference die casting design)

Material: AlSi10Mg

Fabrication: SELECTIVE LASER MELTING

Cooperation Partner:

Monolithic 3D-Printed Rocket Engine

SPACE

Working together with the SLM Solutions Group, a highly complex demonstrator component was developed that highlights the benefits and capabilities of 3D printing. The monolithic rocket engine (injector and thrust chamber) combines integral design – the consolidation of many individual components within one part – and multifunctional lightweight construction. The walling is covered in an integrated and functionally optimized lattice structure and provides not only the required loading capacity but also the option of cooling through active perfusion with the liquid hydrogen. This allows heat to be efficiently discharged from the interior wall of the thrust chamber. The hydrogen is then mixed with the oxygen in the upper part of the engine, conducted through the many injector heads into the combustor, and ignited by a spark plug element. The construction of the engine was designed in such a way as to allow fabrication with minimal use of support structures, which would otherwise have required time and cost consuming post-processing.

Fabrication time: ca. 5 Days

Material: IN718 (comparable to INCONEL 718)

Fabrication: SELECTIVE LASER MELTING

Cooperation Partner:

Biomimetic Wing

AUTOMOTIVE

During the 2017 season, CellCore assisted faSTTUBe, the Formula Student Team of the Technical University of Berlin, in the development of an optimized honeycomb core element for the lower wing component of the rear spoiler system of the FT17 combustion race car. The purpose of the honeycomb core, in addition to its function as a placeholder between the two multilayered carbon fiber laminates, was to absorb greater forces, since the spoiler was connected to the vehicle by four T profiles in the structure. This was achieved through load-specific grading of the honeycomb core element. The core structure was produced in polycarbonate using 3D printing in one part with a wall thickness of each  honeycomb cell of 0.8 mm. The new design concept provides significant weight savings and stiffness improvements compared to the conventional approach. The optimized structure was calculated using a software tool developed in house by CellCore. The component helped the Berlin racing team achieving its best ranking to date and won also the “Best Use of Fiber Reinforced Plastics” award in BASF’s design competition.

Weight saving: 27% (385 g)  |  Overall increase of stiffness increase by more than 300%

Material: Polycarbonate + CFRP-Laminate

Fabrication: FUSED FILAMENT FABRICATION

Cooperation Partner:

Streetcar Carriage Body with self-supporting Hexagonal Framework

RAIL TRANSPORT

CellCore was commissioned by the Panik Ebner design firm to assist in the feasibility validation and optimization of an innovative streetcar carriage body concept featuring lightweight construction and an open design with large window surfaces. The task was to conduct a simulation evaluation on the stability and load-bearing capacity of the carriage body, designed with a hexagonal framework structure, for realistic load scenarios in compliance with the standards of the Association of German Transport Companies. In addition, the optimal dimensions of the hexagonal framework have been calculated (the individual profiles and selection of materials) with the goal of minimizing weight while maintaining the modular honeycomb concept and required load-bearing capacity. Panik Ebner Design is now in negotiations with prospects and potential customers for the implementation of the FavoMove concept.

Cooperation Partner:

References

3D-Printed bi-propellant Thruster Injector

SPACE

Weight saving: 83 % (compared to the reference design)

Material: 718-A LMF (Nickel-base alloy, comparable to INCONEL 718)

Fabrication: LASER METAL FUSION

Cooperation Partners:

Biomimetic Chair Carrier

DESIGN & ARCHITECTURE

Weight saving: 21 % (compared to reference die casting design)

Material: AlSi10Mg

Fabrication: SELECTIVE LASER MELTING

Cooperation Partner:

Monolithisches 3D-Druck Raketentriebwerk

SPACE

Fabrication time: ca. 5 Days

Material: IN718 (comparable to INCONEL 718)

Fabrication: SELECTIVE LASER MELTING

Cooperation Partner:

Biomimetic Wing

AUTOMOTIVE

Weight saving: 27% (385 g) | Overall increase of stiffness increase by more than 300%

Material: Polycarbonate + CFRP-Laminate

Fabrication: FUSED FILAMENT FABRICATION

Cooperation Partner:

Streetcar Carriage Body with self-supporting Hexagonal Framework

RAIL TRANSPORT

Proof and optimization of a new concept for the design of a streetcar carriage body, which combines lightweight construction with an open design with large window surfaces.

Cooperation Partner:

Feel free to contact us!

TRADE FAIRS & EVENTS

We are available to meet you in person at various trade fairs and conference events. You are cordially invited to visit us there.

2019


16. bis 21.09. EMO Hannover
24. bis 26.09. Experience AM (Augsburg)
19. bis 22.11. Formnext (Frankfurt am Main)



2020


21. bis 24.01. Nortec (Hamburg)

CONTACT

Do you have any questions, requests, or comments about our services? Do you need more information?

Feel free to contact us.

OUR LOCATION

CellCore GmbH

Wilhelm-Kabus-Straße 21-35
10829 Berlin
Germany

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