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Simulation Type: Thermodynamics

  • 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…

  • 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.…

  • 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…

  • 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…

  • 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…

  • 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…

  • AIRLIT studio – Studying Natural Ventilation in a Library

    Challenge Evaluate the natural ventilation performance of a library building. Simulate external and internal air flows simultaneously. Identify areas of high wind drafts internally. Suggest options for energy saving and increased occupant comfort. Results Ran external wind simulations based on annual weather data and used the results to feed into the internal airflow analysis. Simulated…