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How we built a 1 : 1 mechanical replica of a hydrogen fuel cell engine

Model optimization and manufacturing - a story of design involvement & engineering experience



At the Outset

We had to build a 1:1 replica of a hydrogen fuel cell engine with an overall size of  

1220 x 1153 x 834 mm.


The Challenge

Optimising a 3D design assembly file of size > 2GB containing over 1000 components for manufacturing.


Our Approach

Our team delved into assembly understanding, model optimisation & component categorization.


Our Process

We began by understanding the assembly and the critical parameters through focused engineering involvement. We categorized the components into machining, 3D printing, fabrication, bought-out, etc., and continued with optimizing the design files for wall thicknesses and assembly. 


The planning & design stage helped us keep the costs for development low. We manufactured the components in batches, tested the assembly & completed the build.


Our Work

Our extensive suite of services encompassing large file handling, 3D sculpting, design for manufacturing, 3D model optimization, and advanced analysis services ensured the seamless evolution of vision into reality.


The Result

This beautiful engine is displayed in the experience zone at Bosch, Bengaluru and has lead to the further development of multiple replicas that my client proudly uses for events and business development meetings. In fact, the engine today is also used as an educative tool to train employees on various industry practices and assemblies.




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