New DSD unit established to help OEMs tackle mounting technical, commercial and cost pressures when delivering new powertrain programmes
Drive System Design (DSD) is expanding its global internal combustion engine (ICE) engineering capabilities to help automakers address increasingly complex powertrain requirements while controlling development costs.
The expanded offering brings together senior technical expertise from Europe and North America with engineering support from DSD’s India operations. The company said the model will allow manufacturers to access specialist engineering leadership closer to their programmes while leveraging its engineering team in India across design, simulation, development, validation, sourcing, and manufacturing.
“Our new global engineering model is designed to bring those priorities together within one DSD division,” said Steve Hunton, Managing Director – ICE at DSD. “Customers can now access senior engineering expertise close to their own programmes while also drawing on a highly experienced engineering base in India.”
The expanded ICE offering integrates DSD’s combustion-engine development expertise with its capabilities in controls, transmissions, electric motors, power electronics, and system integration. This is intended to support conventional as well as hybrid powertrain programmes, including the adaptation of existing engines and vehicle platforms to alternative fuels, electrification, and advanced control strategies.
DSD’s ICE engineering services cover benchmarking, target setting, concept development, detailed design, engine simulation, cost engineering, validation, and production support. The company said it can support both new engine programmes and the re-engineering of existing powertrains, components, and manufacturing processes.
Its alternative-fuel capabilities include methanol, ethanol, biofuels, and e-fuels, supported by combustion development, air-path optimisation, calibration, controls, and validation expertise. The company also supports mild- and full-hybrid architectures, range-extender applications, and related control strategies.
At Aachen, DSD will also showcase an electric motor developed using soft magnetic composite (SMC) technology. The programme involved the concept and detailed design of a three-in-one electric drive unit, virtual verification, prototype manufacturing, and rig testing.
DSD said the resulting motor achieved a 15% reduction in volume for equivalent performance compared with the programme benchmark. The SMC material evaluated during development also had an approximately 70% lower material CO₂ footprint than conventional laminated steel, while offering potential benefits in manufacturing efficiency, recyclability, and motor packaging.
