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Industry: Machinery & Industrial Equipment

  • Kemper – Driving Progress in Drinking Water Hygiene

    Challenges Difficulty accurately modeling nearly-closed valves with small gaps using legacy CAD-embedded CFD solution. Simulation was tied to a single, dedicated workstation, limiting access and preventing parallel work. Engineers spent hours manually “cleaning” CAD models to make them watertight for the solver. Slow design loops with physical prototyping and testing taking up to three weeks…

  • FFE – Code-Compliant Ventilation for Healthcare Projects

    Challenge Understand the dispersion of exhaust gases from multiple sources and evaluate re-entrainment risk under a range of environmental conditions Ensure compliance of exhaust stack and ventilation design against ASHRAE 62.1 guidelines Validate whether infrastructure can safely support upgrades Results Used CFD simulation to verify that the exhaust plumes did not impinge on any of…

  • Emrgy – Designing Hydro Turbines for Irrigation Canals

    Challenge Designing vertical-axis turbines for non-disruptive canal installation presents complex fluid dynamics challenges. Emrgy’s design goals extend beyond maximizing power output; they must also minimize hydraulic disruption, maintain acceptable upstream water levels, and preserve flow conditions vital to irrigation system operators. A key challenge in deploying these systems is understanding both localized and large-scale hydrodynamic…

  • Anchor Light – Enhancing Water Filtration Technologies

    Challenge Diagnosing the root cause of leaks in a water filtration unit that failed a 100,000-cycle pressure test, with initial speculation pointing to a cracked internal plastic component. Lack of clear diagnostic feedback from the testing lab and no visual evidence of the failure. Expensive or logistically challenging prototype testing for ocean technology components. Results…

  • Siemens Energy – Optimizing 3D-Printed Products

    Challenges Required optimization to push thermal performance to the limits Complex geometry and physics with multiple conflicting goals Long simulation pre-processing and turnaround times with incumbent 3D design software stack Results Fast design iterations and parallel validations using cloud-native simulation Parallel assessment of heat transfer efficiency and pressure drop using CHT analysis Pre-processing times reduced…

  • Reliability Engineering – FEA for High-Impact Machinery Design

    Challenges Designing a 20-foot spreader bar with a 20,000-pound load capacity needed operational within five days. Diagnosing and resolving persistent vibration issues affecting a pulverizing machine. Preventing potential failure modes and evaluating the ripple effects of proposed changes on system reliability. Results Project timelines compressed from weeks to hours using SimScale. Successful and safe deployment…

  • Oxygen8 – Optimizing Air Handling Unit Manufacturing

    Challenges Design a new commercial air handling unit using CFD. Reduce dependence on physical prototyping. Optimize for energy efficiency. Results The Terra V unit was developed for commercial use. The entire product development workflow only used 1 physical prototype, and key design decisions were simulation-driven. The unit is entering production and is installed in offices…

  • Outbound Aerospace – Validating a Blended Wing Body Airliner

    Challenge Validating aerodynamics of blended wing body (BWB) airliners, including the hull, engine installation, and flight control surfaces. Designing the structural integrity of retractable landing gear under worst-case loading conditions. Reducing development costs and shortening timelines in aircraft development. Validating critical aerodynamic and structural design decisions without relying on traditional wind tunnel testing. Results Up…

  • Versogen – Designing AEM Electrolyzer Stacks

    Challenge Design an innovative cell architecture for an anion exchange membrane (AEM) electrolyzer. Develop a cost-effective hydrogen electrolyzer stack optimized for high performance and scalability. Test high-pressure membrane seals to ensure durability and prevent hydrogen leakage under demanding operating conditions. Results Developed an industry-leading AEM electrolyzer cell that exceeds the U.S. Department of Energy’s 2026…

  • cross-ING – Simulation-Driven Design for Additive Manufacturing

    Challenge Implement a simulation-driven workflow for a Design for Additive Manufacturing project Import complex nTop geometry into SimScale repeatedly Re-design cooling components for an electrical race car. Results Developed a simulation workflow as part of the DfAM process, reducing the need for costly 3D printed prototypes. Used the implicit import feature from nTop into SimScale…

  • Cobalt Design – Thermal Management for Outdoor Electronics

    Challenge Design a novel swimming pool chlorinator control unit for the Australian climate. The outdoor product had to work efficiently in external temperatures of 45℃ in direct sunlight. Stay within temperature safety limits for electronic devices. Results The new unit had reduced temperatures in all areas of the device in ambient conditions of 45℃. 11%…

  • Helicus – Optimizing Drones for Medical Delivery

    Challenge Identify drone landing sites on a hospital for medical deliveries. Optimize the aerodynamic performance of a drone. Balance drone load-carrying capacity with weight and power requirements. Results Successfully ran transient wind analysis for 16 wind directions on and around the hospital. Used CFD to simulate drone flight stability in urban areas. FEA is used…