♦FEA & CFD • Engineering Simulation • Frankfurt, Germany
FEA & CFD — Simulation with Engineering Judgment
Virtual testing before you build physical prototypes. Simple structural analysis I execute directly. Complex simulations coordinated through EGS Computers India — with my engineering experience to interpret what the numbers mean.
26 Years Engineering ExperienceEGS India Partnership (est. 1993)10+ Analysis Disciplines
What You Get
The Challenge
You need to validate your design before prototyping — but FEA/CFD software licenses cost €20K-50K/year. German simulation firms charge €120-200/hour. Raw analysis data is useless without engineering judgment to interpret results and recommend design changes.
My Approach
I provide FEA/CFD analysis with actionable interpretation. For simple structural validation of my own designs (pressure vessels, lab equipment), I run SolidWorks Simulation directly. For complex analysis — crash, CFD, nonlinear, topology optimization — I coordinate EGS Computers India while providing setup review and results interpretation.
The Outcome
Save €10K-50K in physical testing costs. Catch design problems before prototyping. 40-60% savings vs German analysis firms. Clear design recommendations — not just data dumps.
Project-based pricing. No hidden markup. Full cost breakdown provided in every quote.
What You Receive
Comprehensive deliverables package
- Analysis ReportResults with annotated images and engineering interpretation
- Design RecommendationsSpecific modifications and optimization suggestions
- Stress/Flow VisualizationColor-mapped results for clear understanding
- Safety Factor AssessmentCritical areas identified with margin analysis
Production Ready Standards
How It Works
1
You Define the Design Question
What design question needs answering? What failure modes concern you? I help define the right analysis approach — sometimes a simple hand calculation is better than complex FEA.
2
Simulation with Quality Oversight
Simple analysis: I run directly in SolidWorks Simulation. Complex: EGS India runs ANSYS/Abaqus/STAR-CCM+ — I review setup and validate results.
3
Actionable Design Guidance
Clear recommendations: what to change, why, and expected improvement. Not just colorful stress plots — engineering judgment on what the numbers mean for your design.
Service Scope
What We Can Deliver
Capabilities We Offer
Scope covered through direct expertise & specialist partners
- Structural FEA (static, buckling, fatigue)
- Lifting & Load Analysis
- Pressure Vessel Validation (ASME)
- Thermal Analysis
- CFD Flow Simulation
- Tolerance Stack-Up Analysis
- Non-Linear Analysis
- Analysis Correlation & Validation
Direct experience in structural FEA and CFD for water treatment. Advanced and specialized simulations delivered through specialist partner.
Service Delivery Model
Simple FEA I execute directly. Complex simulations coordinated through EGS Computers India — certified ANSYS and Abaqus analysts.
| Service | Type | Provider | Oversight |
|---|---|---|---|
| Structural FEA (static, buckling, fatigue) | Direct | Saravana (SolidWorks Simulation) | Hand calculation verification |
| Lifting & Load Analysis | Direct | Saravana (SolidWorks Simulation) | Hand calculation verification |
| Pressure Vessel Validation (ASME) | Direct | Saravana (SolidWorks Simulation) | Hand calculation verification |
| Non-Linear Analysis & CFD Flow | Coordinated | EGS Computers India | Saravana: Setup Review + Interpretation |
| Thermal Analysis & Tolerance Stack-Up | Coordinated | EGS Computers India | Saravana: Results Interpretation |
| Analysis Correlation & Validation | Coordinated | EGS Computers India | Saravana: Results Interpretation |
Structural FEA (static, buckling, fatigue)
Type:Direct
Provider:Saravana (SolidWorks Simulation)
Oversight:Hand calculation verification
Lifting & Load Analysis
Type:Direct
Provider:Saravana (SolidWorks Simulation)
Oversight:Hand calculation verification
Pressure Vessel Validation (ASME)
Type:Direct
Provider:Saravana (SolidWorks Simulation)
Oversight:Hand calculation verification
Non-Linear Analysis & CFD Flow
Type:Coordinated
Provider:EGS Computers India
Oversight:Saravana: Setup Review + Interpretation
Thermal Analysis & Tolerance Stack-Up
Type:Coordinated
Provider:EGS Computers India
Oversight:Saravana: Results Interpretation
Analysis Correlation & Validation
Type:Coordinated
Provider:EGS Computers India
Oversight:Saravana: Results Interpretation
My Process
Problem Definition
Step 1 of our Engineering process
We begin by clearly defining the analysis objectives, scope, and expected outcomes to ensure focused and effective simulation studies.
Step 1 of 7
3-5 days
Problem Definition
We begin by clearly defining the analysis objectives, scope, and expected outcomes to ensure focused and effective simulation studies.
Key Points:
- Define analysis objectives
- Identify failure criteria
- Determine boundary conditions
- Agree on accuracy requirements
Tools & Technologies:
Analysis Scope DocumentPhysics Matrix
Deliverables:
Analysis PlanProblem StatementSuccess Criteria Document
Analysis Capabilities
Structural FEA
Linear & Nonlinear Static
Dynamic & Vibration
Fatigue & Durability
Thermal Stress
CFD & Thermal
Steady & Transient Thermal
Internal/External Flow
Electronic Cooling
Pressure Drop Analysis
Proof from My Career
Structural FEA
Buckling & Lifting Analysis
Structural FEA on MBR module steel frames — buckling analysis under operating loads and lifting load analysis for safe crane handling during installation. Designs validated and released to production.
Structural FEACFD Flow Opt
Air Diffuser Performance
CFD analysis on air diffuser systems to optimize air distribution patterns and minimize pressure drop. Simulation results guided design iterations that improved mixing efficiency.
CFD Analysis2.5× Safety Factor
Pressure Vessel FEA
UF module pressure vessel validated at 6 bar operating pressure with 2.5× safety factor per ASME Section VIII. FEA confirmed structural integrity before prototype fabrication.
Pressure AnalysisEngineering analysis experience from my 26-year career at Mann+Hummel and global engineering firms
Featured Project
MBR Module — Structural & Lifting FEA
Complete structural validation of MBR module steel frame for industrial water treatment. Buckling analysis under operating loads, lifting load analysis for crane handling, and CFD on integrated air diffuser system.
Key Outcomes
- Buckling analysis confirmed structural stability under full operating load
- Lifting lug design validated for safe crane installation
- CFD optimized air diffuser distribution pattern
- Design released to production — modules in field operation
From my career at Mann+Hummel
Professional Endorsements
"Deep knowledge in development and design to manufacturing. His technical expertise and methodical approach have been invaluable to our R&D projects."
D
Dominik Schreier
Technical Director • Research & Development
Long-term professional collaboration
Transparent Pricing
Quick Structural Check
€800–€2,500
1-3 days
Simple FEA on single parts or connections. Direct execution in SolidWorks Simulation.
Includes
- Hand calculation verification
- Same-day start
- Design recommendations
Best For
Bracket analysisConnection validationQuick design checks
Standard Analysis
€2,500–€8,000
1-2 weeks
Complex FEA or basic CFD. EGS India execution with my engineering oversight.
Includes
- ANSYS/Abaqus/STAR-CCM+
- Full report with interpretation
- Design optimization suggestions
Best For
Assembly analysisThermal studiesFlow simulations
Advanced Multi-Physics
€8,000–€25,000
2-4 weeks
Multi-physics, crash, topology optimization. Full analysis with design iteration.
Includes
- Iterative optimization
- Multiple load cases
- Complete redesign guidance
Best For
Crash simulationCoupled analysesTopology optimization
Transparency Promise
Project-based pricing. No hidden markup. Full cost breakdown provided in every quote.
Need Engineering Analysis?
Validate your design before prototyping. Get expert FEA/CFD analysis with actionable engineering recommendations.
Or email me: saravana@ideinstein.com
What You Get
- Design question definition
- Analysis approach recommendation
- Cost and timeline estimate
- Expected accuracy discussion
26 years engineering experience•Certified simulation partners•Actionable results, not data dumps