websights

Simulation Type: Structural Mechanics

  • 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…

  • 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 —…

  • Pektron – Accelerating Bespoke Automotive Electronics Development

    Challenges Evaluating thermal limits for highly dense PCB designs within aggressively short one-week turnaround windows. Optimizing cost-effective hardware housing materials without compromising strict automotive heat management requirements. Validating custom testing fixtures to ensure strict compliance with the rigorous mechanical resonance standards of a UKAS laboratory. Results Iterated designs digitally to identify thermal bottlenecks, achieving simulation…

  • Harcourt Industrial – Cloud-Native Simulation in Action

    Challenges Need to eliminate high costs and extended lead times associated with outsourcing structural analysis. Struggle to safely optimize material thickness for specialized aerospace access platforms without over-engineering. Require accurate structural modeling of highly complex, weld-free friction joints without exceeding computational limits. Need to overcome rigid hardware limitations that restricted complex, parallel finite element analysis.…

  • 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…

  • Demir Engineering – Simulation-Driven Foundry Design

    Challenges High cost and risk of physical prototyping, limiting innovation. Existing CAD-embedded simulation tools lacking advanced features. Limited experience of advanced simulation tools making simulation unfeasible for intermittent use. Unable to take full advantage of novel manufacturing process to improve component performance. Results Virtual testing with CFD and FEA provided data-driven insights, increasing design confidence…

  • 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…

  • 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…