Development of High-Precision Systems

At AVL, we understand the complexities involved in design and assembling of high-precision systems where mechanical performance, thermal stability, and manufacturability must be perfectly aligned. Our expertise lies in solving challenges such as achieving highly precise and repeatable positioning of components, ensuring stress- and deformation-free fastening of subcomponents—even under surface pressures below 10 MPa—and minimizing thermal deformation during operation of highly sensitive systems (for example semiconductor industry) to prevent drift and distortion.

Concept Design            
We develop concept subsystem and frame designs ensuring robust stiffness and thermal architecture for efficiency and performance with minimized excitation of vibrations. In addition, we develop custom made measurement concepts for your application, enabling precise validation and performance tracking.

Definition, design, and selection of bearing systems       
We develope and select statically determined bearings and fastening concepts, performing detailed tolerance chain analyses that account for operational loads, and integrating adjustment mechanisms such as spacers or actuators for fine alignment (incl. stress-free bearing supports – incorporating isostatic principles and compensating for manufacturing tolerances and thermal deformations).

System Integration
We support your projects with stringent stiffness and thermal insulation or conductivity requirements and help manage complex assembly strategies involving a high number of diverse interfaces. For this we incorporate solid-state joints into our designs to minimize internal forces caused by positioning shifts or thermal expansion We provide engineering solutions with manufacturability aspects, typically supporting machining-based production, even when requirements are not fully defined at the start of development.

Engineering consultancy
We provide engineering consultancy and design optimization using a “fresh eye principle” to refine your concepts and improve overall system performance. All of this is supported by close coordination with suppliers and assembly teams to ensure seamless implementation from concept to production.

Engineering or vacuum application
We  offer design and development  know how for vacuum and clead room technology. This includes materials selection, interaction of gases with surfaces, flow analysis, particle tracking, venting residual gas analysis, vacuum pumps and molecular pumps selection, thermal analysis in a vacuum, incl. radiation simulation (heat radiation), joining techniques (solid state, adhesives), kinematics detergent discharge, wetting and condensation simulation, design for cleaning, contamination and vacuum sealings.

At AVL, we specialize in engineering precision where temperature, mechanics, and dynamics converge. Our team combines deep technical expertise with advanced simulation to achieve unmatched accuracy in the most demanding environments — from milliKelvin thermal stability to nano meter-level mechanical control.

Numerical Thermal Systems & Stability Evaluation and Optimization
Our design optimization process is strongly supported by simulation we simulate thermal systems, including thermal compensation strategies, sensor placement, shielding, and insulation. Our expertise covers heat conduction in diluted gases down to xPa pressures and heat exchange in both standard and ultra-high vacuum conditions. Using model-based development and 0D/1D lumped-mass simulations, we deliver comprehensive thermal management models that ensure steady and transient load control with sub-milliKelvin precision.

Thermo-Mechanical Control
From controlling thermoelastic deformations at the nano meter scale to investigating bolt sliding effects and safety factors, we integrate thermal and mechanical loads in a unified approach. Our designs mitigate thermal drift during operation with exceptional stability, even under combined thermal and static mechanical stresses such as bolt pretension, acceleration, and inertia relief.

Mechanical Accuracy & Structural Integrity
We develop high-fidelity mechanical models, including complex bolt and contact interactions, achieving absolute dimensional accuracy in the micrometer range and below. This enables precision displacement, positioning, and long-term structural stability, even in highly dynamic environments.

Hyperelastic & Advanced Materials
We model hyperelastic and viscoelastic materials with creep, simulating both short- and long-term behavior. This includes expansion of hoses or closed bodies under pressure, bumper systems, and contact devices, ensuring reliability over the full lifecycle.

Vibroacoustics & Dynamics
We provide coupled fluid-structure models for both air and water, apply viscoelastic damping materials, and deliver accurate transfer functions from excitation to pressure or force. Our dynamic expertise spans eigenvalue analysis, PSD vibrational loading, sinusoidal and impulse excitations, and the creation of reduced super-element models for multi-body simulations.

Software and Hardware facts:

• 0D/1D System Simulation and Control Development: Matlab, AVL CRUISE M, GT-Power, etc.
• 3D-CFD Simulation: ANSYS CFX, AVL FIRE
• 3D-FEM Simulation, ANSYS Mechanical, Abaqus
• Requirements Engineering: Doors, Polarion

AVL delivers end-to-end hardware and software development — from initial concept to serial production. Our expertise spans embedded systems, intelligent controls, connectivity, and advanced analytics, ensuring innovative, reliable, and future-proof solutions.

Hardware Development
We design and develop hardware for low- and high-voltage applications, mechanical structures, and innovative technologies through targeted technology scouting.

Development of Firmware & Application Software
Our embedded software development covers Linux, C++, and complex driver creation. Using model-based development, feedforward, and model predictive control, we deliver precision control functions for complex systems.

Software Testing & Validation
From module testing of software/hardware to test automation and environmental testing, we ensure robust, reliable performance under all operating conditions.

Supplier Management
We handle supplier sourcing, selection, qualification, and auditing, guaranteeing consistent quality and dependable supply chains.

EMC Simulation
We provide analog and 2D/3D EMC simulations, design support, and EMC testing to ensure compliance and resilience against electromagnetic interference.

Data Intelligence & AI
Our solutions integrate data analytics, machine learning, and predictive maintenance to optimize performance and anticipate issues before they occur.

Safety & Security
We perform safety and cybersecurity development, risk analysis, and compliance with the latest industry standards.

Development Methodology and Failure Mode & Effects Analysis (FMEA)
Through gap analysis, efficient process and toolchain setup, and CI/CD pipeline implementation, we streamline development for maximum efficiency. We identify potential errors, assess their impact, and define preventive countermeasures to ensure product reliability.

At AVL, we know technical materials from the whole part to the atom. Whether ensuring that things are done right from the start or providing solutions when something goes wrong, we deliver comprehensive expertise in materials research, characterization, benchmarking, and failure analysis.

Research & Development

• Materials R&D: Metals, polymers, ceramics — from microstructure to full-scale applications.
• Material Characterization: Physical properties, thermal conductivity, thermal capacity, chemical composition, and microstructural analysis.
• Benchmark Studies & Data Analysis: Comparative performance evaluation to guide design and sourcing.
• Guidelines, Reports & Certification: Clear documentation for compliance and decision-making.
• Test Planning & Management: Custom test programs ensuring accurate, reliable data.

Design & Simulation

• Decision support through material input data and specification assessment.
• Drawing checks for correct material integration.
• Guidance on preferred materials and compliance with restricted substance regulations (RoHS).

Production Engineering

• Process quality assurance, batch testing, and prototype validation.
• Comparison with specifications and process improvement initiatives.
• Supplier quality assessment including inclusion rating, porosity analysis, and defect evaluation.

Service & Recycling

• Failure analysis for wear, corrosion, fretting, and cavities.
• Materials substitution for performance, cost, or compliance benefits.
• Materials aging evaluation and recycling/disposal strategies.
• Task force support for urgent issues.

Testing & Evaluation Capabilities

• Mechanical testing (static, fatigue, hardness).
• Process and material inspections per industry standards (technical cleanliness, porosity, phase analysis, heat treatments, graphite form).
• Coating evaluation (adhesion, thickness, composition).
• 3D profiling and surface roughness measurement.
• Screening for hazardous substances (RoHS).