Engineering Services

BCS provides Engineering Services that acts as comprehensive support across the complete engineering value chain for BAUER Group entities, covering mechanical design, structural analysis, simulation, and operator-training solutions. The team works closely with global stakeholders to transform functional requirements into practical, reliable, and manufacturable engineering outcomes for heavy mechanical equipment and complex foundation machinery. With capabilities in concept design, product development, detailed 3D modelling, engineering calculations, FEA-based validation, failure analysis, lifecycle support and simulator technologies, BCS helps improve product reliability, safety, performance, and maintainability. By combining domain knowledge, advanced engineering tools and a strong understanding of BAUER equipment, the Engineering Services team contributes to faster development cycles, better design decisions, continuous product improvement, and realistic training environments for safe & efficient equipment operation.

Design Engineering Services

BCS Mechanical Design team supports the complete product development lifecycle to deliver innovative, reliable and manufacturable design solutions for our global subsidiaries. 
From concept, development and engineering validation to manufacturing support and product improvement, we provide end-to-end engineering expertise for heavy mechanical systems.

Our capabilities include:

Concept Design, Engineering Calculations & Product Development:

Development of engineering concepts from functional requirements through production-ready designs, including preliminary structural validation using analytical hand calculations and SolidWorks Simulation to support concept validation.

 

Mechanical Design of Heavy Equipment:

Design and development of welded and bolted structures, heavy mechanical assemblies and machine components with 3D Modelling, detailed manufacturing drawings & technical ownership using SolidWorks.

Failure Analysis & Design Improvements:

Investigation of field failures through engineering analysis, structural assessment and design validation to identify failure mechanisms and implement design improvements for enhanced stiffness, reliability and product life cycle.

Product Lifecycle Engineering Support:

Provide engineering support after production through ECN/ ECM activities, manufacturing support and continuous product improvement throughout the machine life cycle.

OEM Part modelling & Legacy Data Migration:

Creation of accurate 3D CAD models from OEM components and conversion of existing 2D-AutoCAD drawings into fully parametric SolidWorks models and assemblies.

Building Information Modelling (BIM):

BIM support for product development department, plant layouts and product data management.

Engineering Data & PLM Support:

Support for DocuWare, Part Publisher and engineering documentation.

CAD Administration:

Management of CAD systems, user training in accordance with the latest CAD guidelines, CAD release migration testing, rollout support, system monitoring and issue resolution.

Finite Element Analysis (FEA)

Our Structural Analysis & FEA team delivers advanced simulation and engineering analysis services to support the development of safe, reliable, and high-performance products throughout the product lifecycle—from design validation and structural assessment to optimization. 
By leveraging advanced simulation technologies, industry-leading software, and internationally recognized engineering standards, we provide predictive insights into structural behavior, enabling informed engineering decisions, accelerated product development, and optimized product performance.

Our capabilities include:

Advanced Structural Simulation:

Delivering Finite Element Analysis (FEA) solutions to evaluate structural integrity, validate product safety and performance, identify design improvements, and optimize components for weight reduction, cost efficiency, and enhanced durability.

Comprehensive Engineering Assessment:

Performing linear and non-linear structural analyses using Siemens NX Nastran / Simcenter, complemented by static and fatigue strength assessments in accordance with recognized engineering guidelines such as FKM Guidelines and VDI 2230 for welded, non-welded, and bolted structures.

Bauer Simulator Solutions

The Bauer Simulator Solutions team develops interactive, real-time applications that recreate complex operational environments and processes in a controlled digital setting. By combining software engineering, 3D visualization and domain knowledge, the team delivers intuitive and reliable solutions for training, demonstration, testing and process understanding. 
The Bauer Foundation Simulator is a key application of this competence, supporting realistic operator training and the safe evaluation of foundation-equipment operations.

Delivery and Lifecycle Management

  • Development of real-time applications, for research, training, testing and demonstration
  • Accurate and precise representation of equipment behaviour and operational processes
  • Expertise from a hands-on, professionally trained and multidisciplinary team
  • Design and operational representation in compliance with applicable machine standards with hands-on approach.
  • Application of kinematic systems and mechanical principles for realistic movement and interaction
  • Integration of intuitive interfaces, 3D visualization, software, CAN hardware and external controls
  • Configurable cases, performance optimization, quality assurance, ergonomics and long-term technical support
  • Structured planning based on clearly defined requirements and priorities
  • Coordination with technical experts, SME and international stakeholders
  • Transparent monitoring of milestones, risks and dependencies
  • Controlled management of requirements, changes and software releases
  • Regular technical reviews, testing and documentation
  • Continuous improvement focused on maintainability, reliability and scalability