OEMs & Tier-1 companies
Additional senior capability for process and materials development, numerical validation, supplier collaboration and applied industrial R&D.
Advanced Engineering Lab - AElla GmbH i.G.
Make your hardest
Make your hardest
engineering decisions
with confidence
AElla is an external advanced-engineering and applied-R&D lab for OEMs, manufacturers, suppliers and equipment builders. We combine advanced simulation, manufacturing engineering, materials science and applied research to develop and validate products, processes and engineering methods before you commit to tooling, equipment, qualification or production.
Who we help
Different organisations. One need: stronger engineering capability.
Manufacturers & suppliers
Build stronger simulation, manufacturing-process, materials and development capabilities while reducing production and industrialisation risk.
Equipment builders
Translate machine capability into a validated production case before customer commissioning.
International manufacturers
Strengthen engineering capability, process robustness and technical evidence for demanding European customers and supply chains.
Our mission: accelerating the digital and technological transformation of manufacturing.
Integrated capabilities
Five connected capabilities for difficult manufacturing decisions.
AElla combines advanced simulation, manufacturing engineering, materials science, industrial AI, digital twins and applied R&D to develop, validate and industrialise products, processes and engineering methods.
Process Simulation & Digital Engineering
Validated models, automated workflows and simulation-driven manufacturing-process development.
SIM FACTORY · FEM SPRINT · APP SPRINT
Typical challengesExpensive trials, uncertain process windows, slow or unreliable simulation across forging, ring rolling, extrusion, casting and heat treatment.DeliverablesCalibrated models, process-window & robustness analysis, tool-life methods, automated workflows, fractional simulation leadership.OutcomeFewer physical trials, faster development and more reliable engineering decisions.How to engageSIM FACTORY — Industrialize your simulationFEM SPRINT — Sharpen FEM modelsAPP SPRINT — Engineering tools & applicationMaterials Engineering & ICME
Connect manufacturing history, microstructure, properties and component performance.
FEM SPRINT · R2A LAB · APP SPRINT
Typical challengesUncertain material behaviour, qualification risk and unclear process–property links in high-performance metallic materials.DeliverablesICME workflows, grain/microstructure prediction, local property development, manufacturing-route evaluation, digital qualification support.OutcomeMore robust routes with stronger evidence for qualification and industrial implementation.How to engageFEM SPRINT — Sharpen FEM modelsR2A LAB — From Research to ApplicationAPP SPRINT — Engineering tools & applicationValidated Engineering AI & Applications
Surrogate models and AI-enabled engineering workflows with validation and human oversight.
VAI ENGINE · APP SPRINT
Typical challengesSlow simulation studies, repeated engineering decisions, uncontrolled AI pilots or black-box models.DeliverablesAI-accelerated simulation, hybrid physics–data models, decision-support apps, uncertainty & explainability, documentation and implementation governance.OutcomeFaster decisions with traceability, defined limitations and retained engineering responsibility.How to engageVAI ENGINE — AI you can sign off onAPP SPRINT — Engineering tools & applicationDigital Twins & Virtual Validation
Connect physics-based models with real process and equipment use cases.
D-COM VALIDATE · APP SPRINT
Typical challengesCommissioning and ramp-up risk, equipment–process mismatch and costly late changes.DeliverablesDigital-twin architectures, virtual commissioning, operating-window validation, what-if and lifecycle decision support for defined use cases.OutcomeLower commissioning, investment and ramp-up risk before physical commitment.How to engageD-COM VALIDATE — Commission it virtually firstAPP SPRINT — Engineering tools & applicationApplied Industrial R&D
Move new materials, processes and technologies from hypothesis toward industrial application.
R2A LAB
Typical challengesPromising ideas that stall at report or prototype stage instead of reaching production.DeliverablesChallenge definition, proof of concept, demonstrator, industrial validation, industrialisation roadmap.OutcomeA validated method, demonstrator or implementation roadmap — not only a report.How to engageR2A LAB — From Research to ApplicationAlso available selectively: TECH DD — technical due diligence and industrial-technology assessment for investors and companies.
Technology partnership
Transvalor technology.
Transvalor technology.
Applied to manufacturing challenges.
AElla supports the adoption and industrial application of Transvalor simulation technologies across the DACH region, helping manufacturers turn advanced FEM capabilities into practical engineering value through expert application support, engineering methods, validation and implementation.
Credibility
Built on real industrial depth
AElla is founder-led by Dr.-Ing. Mauricio Santaella — with more than two decades across research and industry, combining manufacturing, simulation and materials expertise with the ability to connect technical decisions to industrial strategy, investment and implementation.
MBA, University of Oxford - connecting engineering, strategy and industrial decision-making
Dr.-Ing., RWTH Aachen — Materials Science & Metal Forming
B.Sc. / M.Sc., UNICAMP (State University of Campinas) — Materials & Manufacturing
Developer of a published tool-life prediction method — available in Forge® since 2013
Experience developing and operating AI-assisted and automated simulation workflows at industrial scale
The company
Advanced Engineering Lab
AElla stands for Advanced Engineering Lab — with a twist. Aella — meaning "whirlwind" — was also a fierce Amazon of Greek mythology known for agility, speed and forward motion. That's the spirit we bring to engineering.
Bring us the industrial problem that has no simple answer.
contact@aella.engineering