We offer high-quality engineering services in the field of light metal casting – since 1999.

Engineering Services

Comptech Rheocasting

Rheocasting is an innovative aluminum casting process that can offer significant material and process advantages. Rheocasting enables components with optimized mechanical properties and minimal porosity. To achieve this, the melt is pre-treated in a standard cold-chamber die-casting machine before pouring and converted into a semi-solid slurry.

We support you in the successful introduction of this process by:

Technology Integration | We plan and optimize your plants for Rheocasting.

Component Development | Our experts advise you on the casting-friendly design of your products.

Training | We offer hands-on seminars to qualify your team for the new process.

Process Optimization | We improve your processes through simulations and quality assurance.

For several years, we have been actively developing Rheocasting solutions and contributing our expertise to these innovative areas. A special result of our work is a Rheocasting-capable solver for FLOW-3D Cast, which is unique in the industry. This development was carried out in partnership with Comptech AB – Sweden, which in our view offers the most efficient process for slurry production.

Referring Documents: How to develop a Rheocasting Process

Your Contact for Rheocasting

Timo Ehnert

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Phone: +49 6224 9908 17

Industrial Engineering

Planning and design of production facilities | With focus on automotive light metal casting and subsequent processes. We have extensive knowledge of tools, industrial processes and furthermore a wealth of manufacturing experience. The lowest possible manufacturing costs while maintaining the required component properties is a priority.

Project planning of technical building equipment | Especially for light metal foundries we plan and dimension the cooling water supply with heat recovery as well as the design of air conditioning systems for heating and/or cooling.

Optimization of production structures | Productivity gain, overall plant efficiency (OEE), reduction of manufacturing costs, capacity extension, restructuring.

Relocations | Planning of relocations with a sound of industrial engineering and QM expertise.

Workshops | Workshops are a very efficient kind of support projects such as workshops considering OEE-increase, reduction of cycle time, restructuring of production lines, reduction of production costs, increase efficiency of the production-system, reduction of scrap rates and casting suited component design.

Sounding Board | We are available as a „sounding board“ for your project team such as for project reviews. The costumer identifies - short term - important additional information and/or gets a second opinion provided by an independent partner.

Your contact for industrial engineering and production planning

Fabian Prügner

Mail@FabianPrügner

Phone: +49 6224 9908 0
Process Engineering

We support you in projects related to improvement of production processes. Our focus is on light metal casting and subsequent processes.

Optimization of production processes and production equipment | Increasing output, improvement of product quality, reduction of scrap rates, improvement of process repeatability, reduction of production costs, the increase of plant OEE and related topics.

Casting suited component design | We support your component development by early reviews of the component geometry with consideration of casting suitability, such as:
- Temperature field analysis
- Determine the casting position (position of the component in the mold)
- Development of the casting system (mold filling and feeding)
- Casting suitable optimization of the component geometry by carrying out mold filling and solidification simulation
- Reporting
Developing casting processes | We plan your casting process, beginning by checking the geometry of the component up to supporting your production staff during implementation and ramp up.
- Temperature field analysis
- Determine the casting position (position of the component in the mold)
- Development of the casting system (mold filling and feeding)
- Conceptual design of the mold and consulting the mold manufacturer under consideration of casting suitable design
- Supporting your production staff during ramp up
Casting defect trouble-shooting | We analyze casting processes and casting defects with special tools and high grade expertise to define adequate countermeasures. PE effectively manages this topic by running own casting simulation software. It allows us to perform in house temperature field, mold filling and solidification analysis.

Your contact for topics related to the casting process

Martin Braus

Mail@MartinBraus

Phone: +49 6224 9908 0
Quality Engineering

Designing your quality management system as well as supporting you by operative quality management is our business. Especially for casted parts we offer extensive know-how.

Quality planning, ramp-up management and phase-out management | Operative quality management during product development process, serial production up to EOP (End-Of-Production).

Supplier management and supplier development | Supporting your supplier to effectively close quality gaps and reach satisfying shipment rates.

Task force | Intensive on site project management to overcome critical technical situations.

Quality management system | Consulting, designing and optimization of QM-systems regarding international revisions in particular ISO 9001:2015 and IATF 16949:2016.

Training | Seminars focusing on Quality Engineering.

Your contact for QM topics and supplier management

Martin Braus

Mail@MartinBraus

Phone: +49 6224 9908 0
Consulting

Technical consulting on all aspects of series production with a focus on efficiency and costs.
- Restructuring | Operational Execllence
- Operational Due Diligence
- Digitalization strategies
- Manufacturing footprint strategy (make or buy)
- Identification of savings potential
- Taskforce and PMO
- Cost and value engineering
Your contact for strategy and consulting topics

Fabian Prügner

Mail@FabianPrügner

Phone: +49 6224 9908 0
Campus Seminars

Project Engineering offers practice-oriented seminars in the field of:

Light Metal Casting | Seminars imparting the casting methods gravity, low pressure and die casting as well as seminars on casting simulations and casting defects.

Quality management | Seminars on „PPF procedures“, „special features“, 8D, FMEA and Q methods.

Project management | Seminar topics are failure management, leadership and personality, conflict management, self-organization of executives, systemic project management.

We collated in 2014 our seminar offering by establishing Project Engineering Campus. The Seminars are available in German or English.

They can be located in Heidelberg or take place as in-house seminars at the customers site. Those seminars allow to be tailored individually to the customers requirements.

Seminar capacities are limited to 15 people. Employees and managers in quality- and supplier management, purchasing, development, production and industrial engineering are the most typical participants.

Download seminar program

Your contact for seminars and workshops

Timo Ehnert

Mail@TimoEhnert

Phone: +49 6224 9908 17
Business Development

Are you aiming to attract German and European OEM as customers for your products?

We know the culture and rules of OEM‘s and can support you efficiently!
- We act as your German or European representative,
- establish and maintain contacts with potential customers,
- act as local contact for your customers,
- support you and your employees in the various project phases,
- train your employees in the customer processes and behaviors,
- support you in qualifying your company as an approved supplier.
Your contact for international business

Detlev Hessler

Mail@DetlevHessler

Phone: +49 6224 9908 21
Rheocasting

Rheocasting is an innovative aluminum casting process that can offer significant material and process advantages. Rheocasting enables components with optimized mechanical properties and minimal porosity. To achieve this, the melt is pre-treated in a standard cold-chamber die-casting machine before pouring and converted into a semi-solid slurry.

We support you in the successful introduction of this process by:

Technology Integration | We plan and optimize your plants for Rheocasting.

Component Development | Our experts advise you on the casting-friendly design of your products.

Training | We offer hands-on seminars to qualify your team for the new process.

Process Optimization | We improve your processes through simulations and quality assurance.

For several years, we have been actively developing Rheocasting solutions and contributing our expertise to these innovative areas. A special result of our work is a Rheocasting-capable solver for FLOW-3D Cast, which is unique in the industry. This development was carried out in partnership with Comptech AB – Sweden, which in our view offers the most efficient process for slurry production.

Leverage our expertise to make your production more efficient and future-proof.

Your Contact for Rheocasting

Timo Ehnert

Mail@TimoEhnert

Phone: +49 6224 9908 17
Sparring Concept and Subscription Option

Cast Process Optimization in Dialogue | You bring your expertise and challenges – we analyze, question, and develop the best possible solution for your casting processes together with you. Our sparring approach ensures that no detail is overlooked.

Production Improvement through Continuous Exchange | Regular consultations and in-depth analyses help us assess your production processes in real-time. We will discuss cycle times, scrap rates, and plant efficiency together and develop specific optimization measures.

Factory & Plant Planning with Your Team | Planning is a dynamic process – we act as a critical but constructive sparring partner, challenging your team, opening up new perspectives, and developing innovative solutions.

Subscription Model – Efficient Collaboration without Bureaucracy

Planned Costs | through a flexible annual budget
Direct Exchange | via phone or web meeting without delays
Quick Response | to acute challenges
More Efficiency | through reduced quotation and ordering processes

Why Sparring with Us?

Question & Develop | We challenge you to find the best solution.
Experience & Expertise | Our team brings deep industry knowledge.
Partnership Approach | We work with you, not just for you.

Your Contact for Sparring and Subscription Model Topics >

Martin Braus

Mail@MartinBraus;

Phone: +49 6224 9908 0

Project Engineering - Engineering as a passion!

Management

Project Engineering was founded in 1999 by the managing directors Dipl.-Ing. Eduard Schröder and Dipl.-Ing. Martin Braus. Both have their roots in the automotive industry and worked for Kolbenschmidt Pierburg AG and DaimlerChrysler AG in Germany and abroad for several years before founding the company.

By founding Project Sales Consulting in 2009, the sales department of Project Engineering was strengthened and the additional field of "Business Development" was established. Dipl.-Ing. Detlev Hessler is co-founder and managing director. He also has his roots in the automotive industry and worked as a project manager for many years.

In 2021, Fabian Prügner moved up to the management of Project Engineering GmbH. He studied foundry engineering in Aalen and has already been working at Project Engineering GmbH since 2017.
Company profile

Project Engineering GmbH has been active as an engineering service provider with a focus on light metal casting since 1999.
With the foundation of Project Sales Consulting GmbH & Co. KG, the Project Engineering Group was formed in 2009.

We support our customers in the fields of industrial engineering, quality planning and supplier management. Short communication channels and flexibility enable us to react quickly to the tasks of a wide range of customers in Germany and abroad.

History:
- 1999 Foundation of Project Engineering GmbH
- 2009 Foundation of Project Sales Consulting GmbH & Co. KG
- 2014 Foundation of Project Engineering Campus
- 2021 Cooperation with VDG Academy
- 2021 Partnership with Comptech AB
Brief profile:
- Engineering-Sevices
- "Hands-on" mentality
- Team oriented way of working
- On-site deployment worldwide
- Automotive and non-automotive
- Seminars and training courses on all common casting processes
- Seminars and trainings in process management and quality management
Downloads

PE-Leistungsüberischt deutsch (pdf)

Seminarkatalog 2024|2025 deutsch (pdf)

Engineering Services english (pdf)

Seminarprogram Light Metal Casting english (pdf)

In den Meckeswiesen 3 - 69226 Nußloch +49 6224 9908 0 mail@projectengineering.de

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We offer high-quality engineering services in the field of light metal casting – since 1999.

Engineering Services

Comptech Rheocasting

Industrial Engineering

Process Engineering

Quality Engineering

Consulting

Sparring Concept and Subscription Option

Campus Seminars

Business Development

Rheocasting