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Industry: Manufacturing

  • 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…

  • 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…

  • 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…

  • Metraflex – Reengineering Valves for Higher Efficiency

    About Metraflex The Metraflex Company makes a variety of engineered piping products including expansion joints, expansion compensators, wall penetration seals, pipe guides, pump connectors, strainers, valves, and more. It has been supplying piping specialty products to the commercial HVAC industry since 1958. Visit Website Variable Frequency Drive Valves The Metraflex Company has developed the first…

  • Vebu – Revolutionizing Food Processing Robotics

    Autocado — Accelerating Food Processing In partnership with Chipotle, Vebu has unveiled a new avocado processing bot called Autocado. This device automates the cutting, coring, and scooping of avocados before they are hand-mashed to create the restaurant’s signature guacamole. Chipotle crew members will simply load a case of avocados (~25 lbs) into the device and,…

  • Fusion Modulair – CFD for Workplace Health and Comfort

    Setting the Stage: The Imperative of Occupant Thermal Comfort Heat exhaustion – signs and symptoms of heat exhaustion include headache, nausea, dizziness, weakness, irritability, confusion, thirst, and heavy perspiration. Heat cramps – signs and symptoms of heat cramps include muscle pains usually caused by the loss of body salts/fluids. Heat rash – heat rash is…

  • Bühler – Deploying Simulation Company-Wide

    Challenge Bühler aims to enable more engineers to simulate earlier and make informed design decisions, whilst controlling overheads and managing quality. Challenges include a globally distributed workforce, multiple CAD systems, varying degrees of simulation knowledge, and more. Bühler also has a goal of a 60% reduction of greenhouse gas emissions in its operations by 2030.…

  • Hoenle – Accelerating UV Lamp Cooling Simulation

    Challenges Limited in-house compute power and an on-premise simulation tool couldn’t resolve the turbulent airflow needed for a new, high-power, air-cooled UV lamp. Outsourcing simulation work to third-party contractors meant waiting one to two weeks for even minor design tweaks. A meeting-dependent, linear workflow with contractors made it slow to explore multiple design variants. New…

  • Carbomech – Developing a High-Speed Motorized Spindle

    The Challenge Carbomech wanted to bring to the market a new air bearing spindle equipped with a DC motor which would be able to reach 180,000 rpm during operation. Being a startup, Carbomech could not afford to test all the design proposals they had. Adding numerical simulations early in the design phase of this new…