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Cobra Aero Reimagines the Air-Cooled Combustion Engine Cylinder using Field Driven Design
Technology Category
- Analytics & Modeling - Generative AI
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Aerospace
- Automotive
- Consumer Goods
Applicable Functions
- Product Research & Development
Use Cases
- Additive Manufacturing
- Manufacturing System Automation
Services
- Software Design & Engineering Services
- System Integration
The Challenge
Cobra Aero, a US-based manufacturer of UAV drone engines, faced the challenge of staying competitive in the market. They invested in a Direct Metal Laser Sintering (DMLS) system to redesign key parts of their engine for Additive Manufacturing. The team aimed to achieve multiple advantages, including improved efficiency, weight requirements, and minimal support during manufacturing. They sought alternatives to traditional fin designs for heat transfer and became intrigued by lattice structures used in heat exchanger design. The challenge was to optimize the lattice structure for heat transfer while meeting the performance and manufacturing requirements.
About The Customer
Cobra Aero is a US-based manufacturer specializing in UAV drone engines. The company invested in advanced manufacturing technologies to stay competitive in the market. They focused on redesigning key engine parts for Additive Manufacturing to achieve multiple advantages, including improved efficiency and performance. Cobra Aero's team utilized nTopology's field-driven design and simulation capabilities to develop a new product following DfAM best practices. The company aimed to create high-performing products that meet multiple requirements and adapt to market demands quickly. Cobra Aero's innovative approach and investment in advanced technologies have positioned them as a leader in the UAV drone engine manufacturing industry.
The Solution
Cobra Aero used nTopology's advanced modeling capabilities to generate different sizes of lattices with varying strut thickness. They filled the lattice inside their cylinder geometry and terminated it with smooth transitions and fillets between the struts. To optimize the lattice for heat transfer, they used nTopology's field-driven design capabilities to spatially control the properties of the lattice. They utilized multiphysics simulation results, including temperature, airflow velocity, pressure drop, and mechanical stresses, to generate a highly optimized structure. The lattice structure was tightened in areas where conduction was more important and loosened in areas where convection was more important. Once the design was finalized, they used nTopology's slicing capabilities to export a CLI file that was sent directly to the Renishaw AM500 system for manufacturing. Testing showed that the new lattice structure design was more efficient than the fin design, requiring less airflow to maintain proper engine temperature in every loading case and at every RPM.
Operational Impact
Quantitative Benefit
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