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Success Stories

Benefit from our extensive experience in highly demanding industries and time-critical engineering projects. Our success stories demonstrate how we transform complex challenges into reliable, high-impact solutions.

CFD Simulation of a Radial Gas Turbine

The project focused on analyzing the impact of surface roughness in a radial gas turbine scroll. The customer observed fluctuating performance and efficiency losses and sought a deeper understanding of the underlying causes. Our team performed detailed surface roughness measurements and integrated the data into a validated CFD simulation. Variations in surface roughness were systematically studied to assess their effect on boundary layer behavior. The results provided clear insights into critical regions where roughness-induced disturbances occurred, enabling targeted improvements. These findings directly contributed to an enhanced quality management process for tier-2 suppliers.
  • Identification of critical zones where surface roughness must be minimized
  • Achieved a 5% efficiency increase by smoothing relevant area
  • Delivered actionable insights for supplier quality management processes

Lightweight Design for Motorsport

This project addressed the design of critical components for a semi-professional motorsport competition. Early prototype designs had shown failures, particularly in the exhaust system. Our team carried out a complete redesign, ensuring the exhaust system was both flow-optimized and highly durable. The new solution significantly enhanced the turbocharger system performance, leading to higher overall engine power output.
  • 60% weight reduction through smart lightweight design
  • Exhaust system lasting a full racing season
  • +20% higher power with flow-optimized exhaust system

Turbulence Investigation in a Combustion Chamber

This research project aimed to analyze the inner flow regime of a combustion chamber during gas exchange with moving internal parts. The objective was to replicate experimental PIV results using a transient 3D-CFD simulation, starting with RANS and later extending to LES. The project was successfully completed, delivering valuable insights to the research team. Moreover, the scientists were trained in how to adjust and extend the simulation model for future applications.
  • Development of a transient 3D-CFD model with moving parts (RANS and LES)
  • Successful validation against PIV experiments
  • Simulation model applied successfully in further research tasks

Surrogate Modelling & AI for Design Exploration of Internal Flow Geometry

The goal of this project was to accelerate design exploration by introducing AI-based surrogate modelling. The internal flow geometry was fully parametrized, followed by a sensitivity study to determine the most influential parameters. Using Design of Experiments (DoE) methods, the required 3D-CFD simulations were reduced from 500 to 50. The simulations were automated on a high-performance cluster, ensuring efficient use of project budget. The results were used to build a surrogate model of the flow geometry and its drag coefficients. With an accuracy of over 99%, the model replaced the traditional trial-and-error workflow. Engineers can now obtain results 120 times faster, and optimization algorithms even allow the AI to find the best design autonomously.
  • AI surrogate models replaced trial-and-error simulations
  • 120× faster design exploration (from 2 hours to 1 minute)
  • AI optimization automatically finds the best design

Fossil-to-Hydrogen Retrofit of a 6-Cylinder Engine

The aim was to convert a conventional 6-cylinder engine into a hydrogen-powered prototype with zero emissions. Since no CAD data was available, the engine was 3D-scanned and fully reverse engineered. Our work included prototype design of H₂ components, performance simulations in 1D GT-Power and 3D-CFD, as well as a complete redesign of the charging system. The project concluded with successful test bench runs, where pre-calibrated simulation maps were validated. Within just one year, the team delivered a performance-ready H₂ICE prototype, demonstrating our ability to execute highly innovative conversion projects.
  • Achieved 100% of original gasoline power output
  • Zero CO₂ emissions with very low NOx
  • Virtually developed engine validated through test bench runs

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CFD development expertise on demand

Immediate simulation capacity and planning certainty for your development project. Our experts from pre-development and motorsport will help you optimize flow, engine performance, turbo matching, cooling capacity, pressure loss, supplier communication, and much more. If required, we use our own software and computers, so you don’t have to make any investments and can still access state-of-the-art simulation results.
away
6.000 €
plus VAT.
  • No minimum contract term
  • Detailed reports with optimization recommendations
  • Assessment of flow and cooling potential
  • Support in setting up your own CFD department and best practices
  • Engineering services starting at 70 hours/month
  • On-site deployment and integration into your processes if required
  • We can provide our licenses (StarCCM+, GT Suite) if needed
  • HPC hours are billed separately if required
  • Credit for previous payments when converting to a large project
  • Parallel, free review for securing funding
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