The Antenna Research Group (ARG) at the University of Colorado-Boulder was tasked with evaluating the bottom side of a vehicle as an alternative to more conventional antenna placement positions for mounting high-frequency VHF antenna systems. The challenge was to develop a procedure for evaluating the feasibility of bottom placement of HF-VHF antennas on military vehicles. Low profile concealed antennas are often desired for diverse applications across many military and commercial vehicle platforms. However, these tall antennas increase vehicles’ vertical clearance and constitute an easy to identify visual signature, which is undesirable. A vehicle underside can be considered as a viable alternative place for concealment, since it provides enough space to avoid extreme antenna miniaturization. The challenge was to assess and compare propagation losses for antennas at various vehicle positions.

The Murchison Widefield Array (MWA) radio telescope, a precursor to the Square Kilometer Array (SKA), was facing a challenge in characterizing its beam pattern. The beam pattern of the array could be determined using measurement, but this method was time-consuming and required specialized equipment. Therefore, a simulation-based approach was deemed the most practical. The beam pattern is a function of each of the 16 array elements as well as the operational frequency of the system. To model the pattern, each of the array elements had to be excited independently, and at different frequencies within the operation band. The full array beam pattern could then be modeled at an arbitrary steering direction. Previously, the simulation of the beam pattern was conducted using analytical models, but a more rigorous approach was needed where the full array geometry was simulated.

Daimler, a leading producer of premium vehicles, has been using design optimization techniques for many years to maximize performance while minimizing material use and mass. However, the traditional processes of optimizing for different disciplines, such as crash and noise, vibration and harshness (NVH), independently can be slow to deliver a design solution that meets varied attribute targets simultaneously. During the development of a new vehicle variant, Daimler wanted to explore the potential of utilizing a multi-disciplinary approach to optimization (MDO), whereby several attribute performance targets are considered in a single optimization study. The focus of this project was a Mercedes-Benz die cast rear cross member that was not yet meeting its crash and NVH targets. The objective was to increase the stiffness of the casting while minimizing its mass.

The toolmaking industry, particularly in Europe and America, has been facing increased pricing pressure due to growing competition from Asian countries. This has led to a need for innovative and high-quality solutions that offer higher productivity and significantly lower costs per part compared to standard solutions. One of the key parameters for higher productivity is the cycle time, which can be optimized through conformal tempering. However, the challenge lies in reducing cycle time without compromising on the quality of the parts produced. The shorter the cycle time, the greater the number of components that can be manufactured within the same period, significantly increasing the facility’s overall productivity and economic viability.

The citizens of Pozuelo de Alarcón in Spain were seeking a cleaner, more efficient city. They aimed to protect the environment, decrease energy consumption, reduce CO2 emissions, and control expenses. The city faced challenges in financing and managing modern and efficient infrastructures. There was a need to improve the urban environment and the overall quality of life of the citizens, while keeping in mind environmental impact and sustainability. The city council of Pozuelo de Alarcón decided to set specific goals to become a Smart City. These goals included detecting and eliminating any excesses in water and electricity consumption, and controlling expenses. The overarching objective was the enhancement of the quality and performance of urban services to citizens’ lives through sustainability, community and growth.

Kampmann GmbH, a leading specialist in heating, cooling, air-conditioning, and integrated building automation, faced the challenge of reducing physical prototypes and gaining early insights into system performance via a virtual development approach. The company's flagship products, KaTherm HK, a trench unit, and KaDeck, a ceiling system for heating and cooling, had to be customized to the needs of each customer and individual environment. This often required individual design adjustments that had to be tested and approved on site. Before the introduction of simulation, the air-conditioning systems were physically tested, which resulted in longer development time and required greater effort. The challenge was to find a solution that would allow for early testing of functionality and special requirements prior to production, thereby reducing the need for physical prototypes and shortening the development cycle.

The Institute of High Performance Computing (IHPC) was faced with the challenge of developing cost-effective and innovative approaches for modelling, diagnosing and solving electromagnetic compatibility (EMC) problems. The complexity of the electromagnetic (EM) system and environment was ever-increasing, and the institute was tasked with handling electrically-large and multi-scale EM problems such as the antenna placement on large platforms. Additionally, they had to deal with multiphysics problems such as the electrical-thermal-mechanical analysis of composite materials. In a specific project, the institute needed an efficient modelling tool to identify optimum antenna positions and minimize interference between various antennas on electrically large platforms. The geometric model of a proprietary antenna was difficult to obtain from the vendor, necessitating the development of a surrogate model to represent it in the antenna placement simulations on the platform. The antenna-on-platform problem was both electrically-large and multi-scale, and could no longer be practically solved with a fullwave only method.

Kappa Electronics, a consulting firm specializing in motor control systems, was approached by a customer seeking assistance with controlling the motor for a new drone design. The challenge was to develop a robust motor control system for drone applications. The control system needed to be able to handle motor frequencies ranging from 40 hertz to 2000 hertz, and perform well across a wide range of torques and parameter variations. The use of a shaft sensor to get the angle of the rotor flux with regards to the stator frame was ruled out due to cost and weight considerations. The challenge was further compounded by the need to ensure that the drone would not drop from the sky under any conditions.

Sujan CooperStandard, a leading manufacturer of anti-vibration NVH products for automotive companies, faced significant challenges due to the stringent environmental norms and government policies related to pollution control. The automotive industry's pressure to reduce vehicle weight to minimize pollution and increase efficiency put the company under immense pressure to optimize designs and reduce the weight of products and components. Additionally, the fierce competition among automotive companies to launch new products quickly added to the pressure. Traditional methods of designing, developing, and testing products were no longer sufficient to meet the aggressive deadlines set by automotive companies. Sujan CooperStandard needed state-of-the-art software CAE solutions to reduce new product development time and cost while maintaining the product quality standards set by their clients.

Auto Original Equipment Manufacturers (OEMs) are increasingly expecting their suppliers to move up the value chain and become development partners. This involves suppliers participating in joint Research & Development (R&D) activities from the conceptual stage, adopting a more collaborative approach to the entire product development process. The key factors for automotive supplier competitiveness include reduced product development time, first-time-right products, and high-value offerings with superior technology at affordable costs. However, automotive suppliers face challenges in having in-house simulation capabilities compared to OEMs due to budget constraints and difficulties in hiring and retaining expert manpower. Access to relevant data to validate designs and establishing robust virtual/test methodologies to match OEM expectations is another concern for suppliers.

In the western part of the Netherlands, the soil has insufficient bearing capacity to allow for the construction of buildings and houses. To overcome this issue, buildings in this area have been built on timber pile foundations. These foundations have to be fully submerged in water to avoid pile deterioration from rotting and fungi. Property owners were seeking a way to monitor the structural condition of these timber pile foundations to optimize the timing of inspections and maintenance work. However, visual inspections of buildings and structures were often not conducted frequently enough, as they tend to be time-consuming and costly. For local governments, housing corporations, and building owners or managers, knowing the condition of their assets and being informed of any structural changes is key to ensure safety, schedule preventive maintenance, and plan adequately for future investments.

Arcimoto, a company founded in 2007 with the mission to build sustainable transportation systems, faced a challenge in creating an optimized platform for their Fun Utility Vehicle (FUV). The FUV was designed to be a three-wheeled, all-electric commuter vehicle that combined the fun-factor and efficiency of a motorcycle with the stability and protection of a car. The challenges included creating a space frame enclosure for protection, a rear swing arm that could handle load requirements, and maintaining the visual design of the vehicle. As a start-up, Arcimoto also faced budget constraints and the pressure to generate interest in the marketplace and among investors. The engineering team had to ensure the vehicle was strong enough to withstand road conditions, and they also wanted to adhere to cross-industry safety tests, such as the roof crush test, to instill confidence in their product.

Argon 18, a high-performance bike manufacturer, aimed to develop a bike that was stiffer, highly integrated, more aerodynamic, and provided greater efficiency. The challenge was to create a lightweight bike without compromising on structural strength and power. The weight of the product could be the defining difference in the competitive cycling industry. The team’s requirement was for the stiffest bike possible while getting the best aerodynamic results, as the rider would expend a huge amount of power during the track event. Making the bike more aerodynamic often results in making the shape thinner, hence the challenge was to make the frame stiff while at the same time balancing the structure‘s strength and the rigidity. An important aspect of the project was the development of a new aluminum stem to be used by Mr. Hansen in the Flying Lap event which is achieved by the fastest lap from the moving start. The stem would need to be seamlessly integrated to the bike frame, while being firmly fixed to the fork insert.

The challenge was to create an organic-like table structure inspired by natural life forms of Radiolaria. IL Hoon Roh, a renowned architect and designer, was particularly intrigued by the way Radiolaria, a type of zooplankton, forms itself by deliberately creating a hole in its membrane. He began a series of objects known as the “Radiolaria Experiment”, starting with the Fabric Table R (Fabric Table Radiolaria), where he applied a three-dimensional structure to his work by hand-stretching a piece of cloth to create a 3D organic form. However, he was not completely satisfied with the seventh experiment in the series, Table R Ex07. Although he achieved the desired shape, the finished object lacked the intricate parts he wanted to depict and was not structurally perfect.

Wisconsin Precision Casting Corporation (WPC), a precision manufacturer of investment castings, was faced with the challenge of reducing costs of regenerative turbine pump cover investment castings. The challenge was to optimize the structural design and manufacturing process to achieve this goal. The regenerative turbine pump cover was a critical component that required high pressure and close tolerances to perform efficiently. The goals for the redesign were to reduce material usage in the pump’s cover, maintain original strength and performance, and improve casting efficiency. The challenge was further compounded by the need to adapt to evolving trends in casting to meet the demands of various industries and customers.

The construction of the Quinta Torre, a skyscraper in Madrid, presented a unique challenge due to the city's naturally occurring wind loads. These wind loads not only impact the construction of the building but also cause discomfort for pedestrians walking by or staying near the building. The challenge was to predict wind conditions on the ground floor, identify problem areas with potentially stronger wind, and implement counteractive measures in the tower design. Detailed flow studies were required to identify areas of possible discomfort or danger for pedestrians and find optimal design solutions. The project leads needed this information prior to concluding the wind tunnel tests, which could take up to six months.

Ossia Inc., a company revolutionizing the mobility and connectivity of people and industries, faced a significant challenge in demonstrating the safe transmission of power wirelessly from 2-3 meters away. The company's patented wireless power Cota® technology, which is delivered much like WiFi, needed to be proven safe for humans and within the Federal Communications Commission (FCC) mandated Specific Absorption Rate (SAR) limit of 1.6 watts per kilogram. The technology was designed to provide real wireless power through the air and over a distance, even while the device is in motion. However, the safety of this technology was paramount, especially considering the potential effects on objects or living beings that could unknowingly walk into the path of the wireless power transmission.

Alstom, a world leader in integrated railway systems, was faced with the challenge of optimizing an existing component design to be manufactured with casting or alternatively with additive manufacturing technologies. The component in question was a part used in Alstom's Metropolis units in the train bogies to support the anti-roll system. The initial design of the part was found to be much too strong for the workloads it was subjected to, and the safety factor was also a little too high. Alstom's engineers were tasked with improving the design of this existing cast part, with a specific focus on optimizing it for production with metal additive manufacturing. The challenge was to improve the overall design while optimizing material usage, and to explore new production options with additive manufacturing.

The National Composites Centre (NCC), a non-profit UK facility, was tasked with the development of an advanced technology demonstrator, a Sit-ski, using composite materials. The Sit-ski, a device used for sports on mountain slopes by individuals with lower extremity limitations, required a design that would showcase the Centre's capabilities while also delivering performance improvements for the skiers. The challenge was to understand the performance of existing Sit-skis, build kinematic models of the suspension behavior, and design a system that would be lighter and more efficient. The design process needed to consider the use of composite structures at an architecture/system level, and the importance of cost and manufacturability in the product development process.

The International Centre for Automotive Technology (ICAT), a division of the National Automotive Testing and Research Infrastructure Project (NATRIP) Implementation Society (NATIS), is a leading automotive testing and R&D center in North India. ICAT's mission is to integrate advanced automotive technology to support the industry in component development for new classes of vehicles and develop cutting-edge technical expertise to expand upon an impeccable range of automotive services. However, the team faced significant challenges in achieving this mission. Previously, they conducted physical testing of automotive products, a method that risked losing both time and money if the product failed the test. Additionally, the team had to perform complex calculations to solve issues and arrive at accurate designs of products. These issues posed daunting challenges to the team and often turned into time-consuming tasks. To develop ICAT into a Centre of Excellence in component development for the automotive industry, the team needed efficient and validated CAE software tools that would enable them to find appropriate and quick solutions to real-world problems.

The Ryerson’s International Hyperloop Team (RIHT) was faced with the challenge of designing a deployable wheel subsystem, similar to aircraft landing gear, for a Hyperloop Pod that could easily move at speeds under 100mph. The Hyperloop Design Competition, introduced by Elon Musk of SpaceX, was the platform where this challenge was presented. The RIHT, led by Graeme Klim, a Masters Student at Ryerson University, decided to focus on a low speed and emergency subsystem that is similar to an aircraft’s landing gear, which they named the Hyperloop Deployable Wheel System. The team had to submit their design concept to the competition’s first elimination round, which had thousands of entries. After surviving the elimination rounds, the team was invited to the Hyperloop Design Weekend in January of 2016, where they won the Subsystem Innovation Award for their wheel system.

Daimler, a German automotive technology leader, faced a challenge in optimizing the layout of FM, DAB, RKE & TV-antennas in multilayer windscreens. The integration of antennas in windscreens has become popular due to enhanced aesthetics and increased antenna surface area, which enables improved reception. However, the design of such antennas is complex, requiring the ability to analyze electromagnetic interactions between thinly layered dielectrics, thin embedded wires, and the surrounding vehicle body. The vehicle body forms part of the antenna in the frequency range of FM-, DAB- RKEand TV-antennas, leading to the need for the glass antennas to be adapted or redesigned for each car line and variant. Different glass types and configurations can change the impedances of the multiport antennas. Additionally, different antenna concepts are needed for different vehicle types.

Ankers, a company that provides simulation, design, and development services for automotive OEMs and tier one suppliers, was faced with the challenge of determining the thermal influence of brake disks and brake pads on the braking distance of a vehicle. The frictional heat generated by brakes when decelerating a vehicle can have various negative effects on the brake system, including thermal cracks in the brake disks, premature wear or brake failure, and an increased braking distance due to changing friction coefficients at higher temperatures. The goal was to optimize system behavior by understanding and mitigating these effects. The challenge was to show that simulation results would be more accurate when considering the thermal effects via co-simulation and to demonstrate the company's co-simulation competences to its existing and future automotive customers.

Wilson Sporting Goods Co., a leading manufacturer of high-performance sports equipment, was faced with the challenge of supporting contestants in a golf driver design television show, Driver vs. Driver. The show aimed to encourage innovation in the golf industry by having aspiring golf club designers compete to develop a winning design that would ultimately be produced as Wilson’s next driver. The challenge was to provide the contestants with the necessary tools and expertise to bring their designs to life, while ensuring that the designs were technically sound and met the high expectations of consumers in terms of look, feel, and performance. The increasing competition in the sporting industry and the growing demand for faster, lighter, and stronger equipment added to the complexity of the challenge.

PaceControls, a leading technology developer and manufacturer of IoT solutions for the HVACR industry, faced a significant challenge in controlling HVACR equipment. The HVACR systems come in various configurations and sizes, ranging from single compressor/single fan to multi compressor/multi fan units. The technology developed by PaceControls had to be flexible enough to accommodate 10 major HVACR configurations, each with over 200 individual requirements. The challenges included managing requirements and algorithmic complexity, ease of installation and use, accurate estimation of savings, and more. The technology also needed to support Wi-Fi, ZigBee, and 4G LTE communications, and over the air (OTA) firmware update capability.

National Electric Vehicle Sweden (NEVS), an electric vehicle and technology developer, was facing a challenge in accurately simulating and eliminating squeak and rattle noise in the interior of their electric passenger cars. These noises, created when two parts come into contact or are displaced relative to each other, can lead to a perception of poor quality among vehicle occupants. The traditional process of building a prototype, testing material interaction, and correcting problems as they occur was proving to be lengthy and expensive. The company was eager to better understand and predict these phenomena to reduce interior noise and improve ride quality. However, the Interior Simulation Team had not yet used simulation strategies to predict and address squeak and rattle issues.

The Universidad Autónoma del Estado de Morelos (UAEM) in Mexico was faced with the challenge of designing low-cost, lightweight antennas for TV and automotive applications. The goal was to make modern day communications, including TV and GPS, more affordable for the masses, particularly in developing countries. The challenge was particularly significant in the context of TV reception, where the successful transmission of signals to remote areas, especially indoors, was often problematic. The traditional solution, a Yagi array antenna, provided a directed beam towards the TV tower, but the team at UAEM sought to develop an antenna that was smaller, lighter, and improved signal stability.

Woodland/Alloy Casting, Inc., a full-service aluminum casting provider, faced a significant challenge in transitioning a marine exhaust housing part from a lost foam casting to a sand casting. The transition required an updated gating system to maintain the integrity of the part. The company aimed to produce a sound casting while keeping ingates and risers to a minimum, which would allow for a low yield and reduce the time needed to remove the rigging. The challenge was to design a new gating system that would feed the casting from the bottom flange and push the metal to the top of the casting. The traditional approach to testing the new gating system would have involved numerous costly and time-consuming tests, requiring a number of molds to determine the outcome of the new gating system.

CalsonicKansei North America (CKNA), a part of the global automotive parts manufacturer, CalsonicKansei Corporation based in Japan, was facing a challenge with squeak and rattle (S&R) in vehicle interiors. This issue was affecting the quality of their products and customer satisfaction. Despite being experienced in modern Computer Aided Engineering (CAE) techniques, CKNA had not fully explored the potential of using simulation technologies to investigate S&R issues before physical hardware production. Squeak and rattle are two phenomena which occur when two parts of an assembly are in relative motion due to a specific excitation load. The lack of knowledge in S&R methodology was preventing early issue detection, leading to inefficiencies in product completion and potential warranty claims.

The TUfast Eco team from the Technical University Munich, consisting of about 30 students from various fields of study, was tasked with designing, developing, and manufacturing an energy-efficient vehicle to compete in various energy-efficiency contests, including the Shell Eco-marathon. The challenge was to create an entirely new vehicle each year, with no component of the previous year's vehicle allowed to be used. This was to ensure that the technical expertise and development approaches of previous years were passed on to the new team. One of the most important aspects in the development of an energy-efficient vehicle was to reduce the mass of the vehicle. Therefore, the team members were constantly looking for weight-saving potentials, especially when designing the suspension and chassis.