Engine Development

BDN Engineering provides state-of-the-art engine development and trackside testing and engineering services to all range of customers fullfilling any needs. Get the most out of your engine, and let’s win races together!

Come to us if you need

Data driven engine design
F1 technologies
Ultimate performance
Outstanding reliability
Proven track record
Prototype manufacturing
Turn-key solution

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Race engine development is a really complex task, as exceeding the performance barrier is not possible only by sourcing the top level components from the market. The hidden performance is could be unleashed by finding the perfect balance between the different parts. We provides simulation based development services, reducing the extreme cost of the traditional trial and error method. This helps us designing the characteristics of the given engine satisfying all of our clients’ needs whether it is a 1000+ hp drag bike, or a historic rally engine.

References

KAMManufaktur 912c

Koenigsegg Jesko

TC Racing Engines

Team Brothers Racing

How We Work

Step1: CT Analysis

We take the old engine block, cylinder head, or whatever component and put it into an industrial X-ray or other 3D scanning methods.

Step 2: Reverse Engineering

Based on the 3D scan images, we can reverse engineer the whole component into a CAD file, or design a bespoke part that will fit into the design envelope.

Step 3: Iterative design process

After the initial concept, comes the most interesting part. For the actual design process we use:

1D simulations
3D CFD simulations
FEM (Finite Element Analysis)
Generative Design

It takes hundreds of iterations to optimise the geometry, stiffness, weight or cost - depending on the project.

Step 4: Prototyping

For the first tests of a new component, we use quick and cost efficient prototyping methods:

Different types of 3D printing
Other additive manufacturing technologies

Step 5: Manufacturing

At the end of the design phase, we produce drawings and CAD files, and manufacture the component using our trusted partner network - for any parts of an engine with a short lead-time and competitive pricing.

Step 6: Validation

The simulations are only as good as their validation processes. BDN provides a patented combustion analysis - which is used by OEMs and hypercar manufacturers. The measured values are fed back to the simulations as an input parameter, to simulate real world conditions creating 100% trust in the virtual environment!

Step 7: Race Engineering

BDN takes care of the whole process from the first sketch through building and calibrating your engine to trackside support.

Our motorsport engineers are qualified by Cranfield University Advanced Motorsport Engineering, and have multiple years of experience in trackside support, OEM and hypercar development.

Tell us your idesa, and let us make it reality!