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Simulation Type: Multiphysics

  • 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…

  • 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…

  • 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…

  • 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…

  • TEGnology – Building the Wireless Industrial Edge

    Challenges Accurate power prediction requires a validated approach to modeling contact resistance between component interfaces. Thermal design of the housing and clamping system need to evolve in line with mechanical design so that the two work in concert Limited ability to measure internal heat flows with lab testing to inform design direction As a lean…

  • DLR Group – High-Performance Sustainable Building Design

    Challenges Maximizing building efficiency to meet LEED criteria. Broad CFD simulation capability needed to support a global engineering team. Validating condensation-free HVAC performance. Ensuring pedestrian wind comfort and safety on campus Risk and cost management for novel design ideas to avoid late stage design changes and rework. Results Accelerated design iterations 2-3x by running cloud-native…

  • 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…

  • 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…

  • 3P Innovation – Accelerating Cryovial Machine Design

    Challenge Design of the cryoFIL® automated cryovial machine. Carefully design the airflow inside the machine to avoid any contamination of the open vials. CFD simulations of multiple operating points to evaluate air turbulence, stagnation, and unwanted mixing. Results Employed parallel simulations in SimScale to rapidly evaluate many design variants. Early stage design confidence using simulation…

  • DMG – Optimizing Data Center Cooling Efficiency

    Challenge Implementing CFD analysis in-house for mission-critical facilities. Optimizing data center cooling strategies for low energy, reduced cost, and sustainability criteria. Results Brought simulation services in-house. DMG reports a 35% saving on labor costs per project, significantly reducing both time and financial expenditure compared to outsourcing. ASHRAE code-compliant data center cooling. Design Management Group (DMG)…

  • Ilmor Engineering – Race-Ready Parts at Short Notice

    Challenge Ilmor Engineering, Inc. is a globally recognized provider of high-performance engines known for innovative designs that maximize power, durability, and efficiency. Engineering simulation is needed to continuously design new high-performance parts ready for races at short notice. Results Complete system optimization of engine components including structural, thermal, and flow characteristics. Developed a piston during…

  • Energyminer – Optimizing a Micro-Hydropower Plant

    Challenge The Energyfish by Energyminer is a micro-hydropower plant that harnesses the power of water and produces electricity continuously in a river. Energyminer’s engineering team was looking to simulate and analyze the fluid-structure interaction, material selection, structural resilience, and turbine. Results Increase in hydrodynamic efficiency via fluid-structure interaction simulation and optimization. Turbine body refined for…