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Simulation Type: Fluid Dynamics

  • Domin – Engineering Advanced Hydraulic Valves

    Challenges Previous CFD software produced variable accuracy, forcing physical test iterations to close the gap. Locally stored simulation files locked results away from the wider team. Static design review reports created high dependency on the designer’s own judgment of what mattered. Local compute meant simulations blocked designers from other work while running. A new analysis…

  • HIGTEC – Diagnosing Gas Entrainment in Rail Tank Wagons

    Challenges Nitrogen gas was drawn into the suction line during rail tank wagon unloading, causing pressure fluctuations, and risking pump damage. Predicting flow behavior across a full unloading cycle required tracking a moving gas-liquid interface. Plant measurements showed the symptoms of unstable unloading, but did not provide visibility into the internal multiphase flow mechanisms causing…

  • Cflow – Designing Gentler Vacuum Diffusers

    Challenges Fish welfare during transfer depends on flow behavior that cannot be seen from outside the equipment. Concepts chosen on the strength of previous vessels could not be compared against each other before commitment. An unvalidated concept stalls decisions and forces repeated rework of solid models and drawings. Outsourced analysis costs a multiple of in-house…

  • Allegro Energy – Flow Batteries for Grid Energy Storage

    Challenges Need for uniform mixing in large, bespoke electrolyte tanks to ensure battery performance. Microchannel flow architecture in battery cell/stack determines efficiency and pressure drop. Legacy simulation tools running on-premises could not provide simulation throughput needed to keep pace with design needs. Results Multiphase CFD visualized mixing across baffle designs, nozzle depths, and flow rates,…

  • Crestline Coach – Advanced Ambulance HVAC Design

    Challenges Long development cycles driven by slow, sequential build-and-test prototyping process. High costs from creating multiple full-scale physical prototypes for HVAC and structural validation. Limited performance insight from physical tests, making it difficult to diagnose complex airflow, thermal, and structural issues. Legacy in-CAD simulation software creating severe bottlenecks with failed meshes and file corruption issues.…

  • Fourier – Designing a Next-Generation Electrolyzer Stack

    Challenges Standard handbook rules for elastomeric seal design do not apply to the shallow gland geometries required for thin PEM electrolyzer plates. With no previous in-house stack design to reference, the team had no established tolerance bands and no way to predict the effect of manufacturing variation without physical testing. Seal stability under pressurization —…

  • IGS – Using Digital Twins to Drive Innovation

    Challenges Thermal and airflow behaviour in the Growth Tray with Lights (GTL) is difficult to predict due to multiple electrical heat sources interacting with HVAC-driven flow paths. Physical design changes require a full growth trial (roughly three weeks) before they can be released into production. Understanding how component layout decisions affect overall thermal performance has…

  • Catalytic Consulting – Simulation-Driven Hydraulic Design

    Challenges Inefficient media utilization caused by significant dead zones in legacy filtration systems. Existing maintenance protocols requiring hazardous confined-space entries for disinfection. Computational bottlenecks created by expensive, on-premises legacy CFD software. Strict EPA regulatory deadlines for municipal water safety compliance. Results Enhanced media utilization by reducing stagnant dead zone volumes by 27.25%. Engineered an external,…

  • Biogents – Leveraging Cloud-Native CFD

    Challenges Eliminating poorly performing designs early in the engineering phase. Lack of insight into device performance from physical testing. Balancing mechanical suction needs against strict indoor acoustic and noise limitations. Securing scalable computational resources for highly variable, project-based workloads. Results Used cloud-based simulation to visualize airflow and filter out flawed concepts. Adopted computational fluid dynamics…

  • Convion – Reducing Design Cycles with Generative Engineering

    Challenges Needed to recover process gases from harsh chemical and thermal environment Designing a fluidic device, maximizing flow vs. pressure recovery. CFD-driven design optimization process was slow, with single iterations taking hours and full design space exploration requiring months. Deeper design space exploration needed to optimize for packaging constraints as well as performance. Results Used…

  • Merford – Acoustic and Thermal Design of Transformer Enclosures

    Challenges Containing low-frequency tonal noise from high-voltage transformers without restricting necessary cooling airflow. Managing large thermal loads exacerbated by rising global baseline temperatures, which compress allowable thermal safety margins. Overcoming the computational bottlenecks and hardware limitations of legacy simulation software. Meeting tight commercial tender deadlines with generalized estimates that often led to over-engineered solutions. Results…

  • Emil Motors – Magnet-Free High-Performance EV Drives

    Challenges Timely multiphysics modeling of novel induction motor design to drive rapid design process. Ensuring structural integrity of the dual-rotor assembly at high operational speeds Identifying invisible “stray losses” caused by magnetic flux leaking into structural components like the housing and shaft. Mitigating high windage losses caused by air drag inside the casing at tip…