Thalhammer Engineering Solutions

From Aviation to Rail:
Engineering Excellence with Vision

Complex technology, the highest safety standards, and tight schedules – this is my world. For nearly two decades, I have been navigating the highly regulated aviation and rail technology industries with confidence. As a freelance engineer, I support you wherever technical know-how, a hands-on mentality, and a structured approach are required.

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About me

Solid Foundation
Degree in Aeronautical Engineering (University of Applied Sciences)
approx. 8 years
Aviation
Sound practical experience in calculation, design, and liaison engineering (the interface between development and manufacturing).
from 2014
Transition to Rail Technology
Deepening expertise in design, project management, and direct on-site support.
Mid-2019 – March 2026
Entrepreneurial Chapter
Co-founding and significantly shaping Xaleris (initially as Managing Director, later as Authorized Signatory / Executive Vice President) together with long-standing colleagues.
2024
Keeping Pace with Innovation
Further qualification as European Adhesive Engineer (EAE) at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM in Bremen.
Since March 2026
Transition to Freelancing
Following the market-driven liquidation of Xaleris, taking the logical next step: As an independent engineer, I continue to support the majority of my long-standing existing clients and bring this entire portfolio of experience into new projects.

Working Style and Why Clients Rely on My Expertise

Design Meets Structural Analysis: I integrate development and verifiability right from the start. Whether complex FEM calculations or analytical verifications – my design decisions are directly linked to subsequent testing and compliance capabilities. This eliminates unnecessary alignment loops, reduces iteration cycles, and ensures smooth approval/certification.
Experience Meets Pragmatism: Through my years in liaison engineering and on-site client support, I know that plans need to be flexible in reality. I deliver solutions that do not only work on paper or in numerical models, but also in manufacturing and assembly.
Seamless Integration: Whether at a CAD workstation, in calculation setups, or managing ongoing operations – I adapt quickly to existing teams, standards, and tool environments.
Reliability: As a long-standing partner to my clients, I focus on transparent communication, adherence to deadlines, and top-tier engineering quality.

Services

Consulting

Feasibility and concept studies
Technology consulting
- Joining technologies (bonding, riveting, bolting)
- Material selection
Troubleshooting
- Process & ramp-up support
- Maintenance and repair concepts including detailed elaboration
- On-site support

Design & Engineering

3D modeling (concept to detail)
Drawing and bill of materials (BOM) creation
Retrofit and Reverse Engineering

Analysis

Pre-dimensioning
Strength analysis
- Analytical handbook methods (HSB, FKM, Eurocode)
- Numerical Methods
Optimization (lightweight design, costs, functionality)
Fatigue life and durability assessments

Simulation

Finite Element Analysis (FEA)
- Linear
- Non-linear (geometric, material and contact)
- Hyperelastic (adhesive bonding)
Topology and shape optimization
Computational Fluid Dynamics (CFD)