Design—from single cylinder industrial engines to ultra high performance engines

MAHLE Powertrain's design team, being independent of any OEM, work with a wide range of customers developing products ranging from single cylinder industrial engines to ultra high performance engines for road or race applications. At MAHLE we design complete power units or engine systems from concept to production or provide engineers to our customers own design and analysis teams.

Our Approach

MAHLE Powertrain uses the latest Computer Aided Design (CAD) and analysis tools to offer a full range of services to our customers. We draw on the expertise of our 27 specialist engine designers, complemented by our in-house analysis, manufacturing, casting, calibration, research and development capabilities, as well as access to the component and system expertise of the MAHLE Group.

We adhere to a structured approach to product design, based on proven methodologies and quality systems.

MAHLE Powertrain is equipped to support every phase of the product development cycle from concept generation to Start of Production (SOP) design.

Concepts are selected following evaluation against project targets by multifunctional teams of specialist engineers drawn from the manufacturing and engineering functions within MAHLE Powertrain or from within our customers own organisation.


Our Tools, Facilities and Services

CAD Systems

• Established PLM System
• Pro-E Wildfire
• CATIA V4/V5
• IDEAS V12 or 13 (5i)/TDM
• Unigraphics NX

Visualisation and Assembly Tools

• CATIA 4D Navigator/Vis Mockup/Pro-Renderer
• 3D Caliper (Wall thickness)

Data Transfer Tools

• FTP/Native or Neutral Formats (IGES, Step, STL, etc)
• Odette
• Open DXM
• Fusion DX

Customer Benefits

Using industry best practice modelling techniques, MAHLE Powertrain creates robust and flexible component models ready for tooling design, styling assessment, design analysis, mould flow analysis and packaging exercises. With experience in all engine systems, including complex cylinder heads, cylinder blocks, cranktrains and valvetrains, we have the tools and the expertise for cost-effective optimisation of the whole powertrain.

The combination of robust quality systems, in-house manufacturing capability, decades of experience in designing for manufacture and access to the engineering software and hardware resources of the MAHLE product lines allows the MAHLE Powertrain design team to offer our customers effective production design optimisation with Supplier Quality Assurance (SQA) support, benchmarking and Value Engineering Services.


Project Examples

• MAHLE Advanced downsizing demonstrator engine and vehicle - 30 bar Brake Mean Effective Pressure (BMEP) and up to 120 kW/L (single and 2-stage turbocharger)
• Single cylinder research engines
• Range extender engine
• Audi V10 Bi-turbo (650ps, 750Nm)

• GDI, quad cam phasers, dry sump, integrated exhaust manifold and turbine housing