From CAD to Cosmos: How Co-Engineering Reduces Development Risk

“Hardware is hard” – what has become a common saying in the software world is a daily, existential reality for founders in the deep-tech, mechanical engineering, and aerospace sectors. While code can be compiled flawlessly as often as desired, errors in physical components mean skyrocketing costs, failed funding rounds, and months of delays.

A perfect CAD model is worthless if it cannot be manufactured economically or with physical stability. Feramic AG therefore positions itself not as a passive contract manufacturer, but as an agile co-engineering partner that shares the burden of technological risk alongside founders.

Radically Shortening Time-to-Market through LPBF

In the high-tech sector, the speed of iteration cycles determines a startup's survival. 3D metal printing (Laser Powder Bed Fusion, LPBF) breaks down traditional restrictions. Startups can realise highly complex prototypes directly from the 3D model without having to invest in expensive moulds beforehand. This allows development teams to correct errors in days instead of months.

Innovation at the Frontier: Practical Examples

• Project PEGASUS (ARIS/ETH Zurich): The world’s first student-developed, liquid-fuelled RDRE rocket engine made of copper was printed at Feramic – a manufacturing feat that would have been impossible using conventional methods.
• SpaceHopper: For this hopping space robot (tested by ESA), Feramic produced highly complex structural parts where every gram and absolute integrity counted.

Co-Engineering & DfAM: Theory Meets Reality

Many brilliant systems fail due to a lack of manufacturability. Our engineering team bridges the gap between theory and practice with Design for Additive Manufacturing (DfAM). Already in the concept phase, we critically assess whether a component must be manufactured additively or whether hybrid manufacturing – the combination of 3D metal printing and CNC post-processing – is more economical.

Performance Boost through Integral Design

• AMZ Racing Wheel Carrier: Through topology-optimised integral design, internal cooling channels were integrated directly. The result: minimal mass with maximum stiffness.
• TPMS Structures in Radiators: The use of Triply Periodic Minimal Surfaces (TPMS) increased the ratio of heat performance to weight by an impressive 80%.

Scalability Without Investment Risk

Investors demand scalability from the start. Feramic offers a fully digitalised process chain (ISO 9001) and enables:

• No Minimum Order Quantities (MOQ): Economical production starting from a batch size of 1.
• Highest Swiss Quality Standards: Comprehensive documentation for demanding auditors.

Feramic is your technological backbone. We absorb the manufacturing risk and bring your innovations to the road, the industry, or space in record time.