Modeling, Simulating, and Optimizing Fluid Dynamics Processes

Simulation and Digital Twins for Fluid Dynamics Processes in Industry

We combine mathematical and physical modeling, high-performance flow simulation, and systematic process optimization into an end-to-end workflow. Building on this foundation, we develop customized models, simulate complex processes using specialized software, and create digital twins for industrial applications.

Our solutions are used wherever fluid flows play a central role. The combination of modeling, simulation, and data analysis creates a solid foundation for decision-making. Companies gain detailed insights into their processes, identify opportunities for optimization early on, and can design and operate fluid flow systems more efficiently.

Flow Simulation for Complex Fluids and Materials

Our expertise in fluid dynamics and the software tools we have developed cover a broad spectrum – from highly turbulent air flows to complex non-Newtonian fluids such as suspensions and multiphase flows. In addition, we simulate the interaction of flows with fine structures such as particles, fibers, or films. These models are used, for example, in injection and infiltration processes as well as in cooling, heating, and drying processes.

For filters and other porous structures, we use multiscale approaches. In doing so, we combine detailed models of individual material structures with simulations of the overall process. In addition, we employ methods of parameter and geometry optimization to determine suitable process parameters and design components to optimize flow.

Digital Process Development for Industrial Applications

Our approach encompasses the modeling, simulation, analysis, and optimization of fluid dynamics processes. This end-to-end workflow accelerates digital process development and lays the foundation for robust and reliable industrial solutions.

Our methods and software solutions are used in a variety of industries, including plastics processing, the textile industry, the biotech and pharmaceutical industries, energy and process engineering, and the development of automotive components.

FOAM

Our FOAM solver simulates the expansion process of PU foams in any given geometry and offers the possibility to calculate the foam formation process as well as the resulting foam density in advance.

GRAIN

GRAIN is an infrastructure for the design of products and processes which involve granular media.

FLUID

The software solution, Complex Rheology FLUID Solver, has been developed to simulate the melting and flow behavior of polymer suspensions, such as in the injection process of a fiber suspension.

Example Projects

 

Additive Manufacturing with 3D Foam Printing

Custom-made lightweight components from the 3D printer can be used to create sustainable and highly individualized products.

 

Innovative Designs for Optimized Flow Fields in Reactors

We optimize flow fields to increase the efficiency and performance of electrochemical reactors.

 

Efficient Multiscale Processes for Short-Fiber-Reinforced Plastics

In cooperation with Bosch, we have developed a multi-scale simulation method.

 

Simulation of the Production of Batteries

We simulate battery production processes to make them as efficient as possible without negatively affecting the product properties.

 

Better Understanding Hydrogen Electrolysis Through Simulation

In the project »H2-D« we focus on the shape design of bipolar plates.

 

Simulation of PU Foam Expansion in Car Seat Manufacturing

Joint project in cooperation with Fehrer Automotive and Audi in which our software FOAM is used and further developed.

 

 

Designing Polymer Spin Packs for Fluid Dynamics

Our software solutions simulate spin packs to better understand the flow behavior and to optimize the design. 

 

Potting Process Simulation of Electronic Devices

In the project SOVEB we simulate this process with FLUID so that companies can optimize their production steps.

 

Simulations Optimize the Design of Actively Ventilated Face Visors

Our experts use simulations to support DesCap GmbH in optimizing the design of face visors.

 

Simulation of Granular Mass Flows

Application and project examples for the simulation of granular mass flows.

 

Analysis and Optimization of a Texturing Nozzle

In machines for the production of carpet fibers, the filaments are first stretched over heated galettes, accelerated subsequently in one or more air shafts by diagonally injected air flows, and finally joined in a lamellar channel for frilling.

 

RIM Processes of Polyurethane Foams

In the project FoamInTextil we simulate the foam filling process of Polyurethane foams.

 

Simulation-based Design of a Nonwoven Spunbond Plant

A new nonwoven spunbond plant has been constructed on the basis of simulation results.

 

Characterization and Modelling of Long Fiber Reinforced Thermoplastics

We contribute our simulation expertise to the AiF project.