Contact UsBackground
MagLev Aero is a cutting-edge startup in the electric aviation industry, specializing in highly efficient electric propulsion systems for both vertical and horizontal flight. Initially focused on unmanned systems, MagLev Aero has its sights set on expanding into both military and commercial applications. With a lean team of dedicated engineers, the company is pushing the boundaries of electric propulsion technology, developing solutions that integrate electromagnetics, aerodynamics, and structural mechanics.
At-A-Glance
Technology Used
- Ansys Maxwell
- Ansys Fluent
- Ansys Mechanical
- Ansys Workbench
Challenge
- Low-fidelity simulation tools lacked precision, limiting accurate thrust and torque predictions.
- Needed an integrated multiphysics solution for electromagnetics, aerodynamics, and structural analysis.
Outcomes
- Improved accuracy with high-fidelity simulations matching test data
- Accelerated design cycles using automated workflows
- Reduced costs by minimizing physical prototypes
- Enhanced multiphysics integration for optimized electric propulsion
- Seamless CAD integration for efficient design updates
Challenges In Electric Propulsion
As a seed-round startup, MagLev Aero faced significant challenges in optimizing their propulsion system designs. Prior to adopting Ansys simulation tools, the team relied on lower-fidelity software packages that lacked the precision necessary for complex aerodynamic and electromechanical analysis. This limitation prevented them from accurately predicting thrust and torque numbers for their rotor system, leading to potential inefficiencies and increased development costs.
Additionally, MagLev Aero required a simulation solution that could integrate multiple physics domains—electromagnetics, thermal analysis, structural mechanics, and aerodynamics—into a cohesive workflow. Traditional tools were insufficient for capturing complex phenomena such as flow separation, which impacted rotor performance and overall design efficiency.
The Solution
To address these challenges, MagLev Aero turned to SimuTech Group, an Ansys Apex Channel Partner, for guidance and access to high-fidelity simulation tools. After evaluating various software solutions, the team selected Ansys for its industry-leading capabilities, particularly in computational fluid dynamics (CFD), finite element analysis (FEA), and electromagnetics (EM).
The Benefits
Since integrating Ansys simulation solutions with the support of SimuTech Group, MagLev Aero has realized significant benefits:
- Improved Accuracy: The ability to transition from low-fidelity design codes to high-fidelity simulations allowed the team to match spin tower test data, enhancing confidence in their designs.
- Faster Iteration Cycles: By leveraging Ansys’ automation tools, such as PyFluent, MagLev Aero accelerated design iterations, reducing computational time and improving workflow efficiency.
- Cost Savings: Early-stage validation through simulation reduced the need for costly physical prototypes, enabling the team to optimize designs before fabrication.
- Multiphysics Integration: The seamless coupling of electromagnetics, thermal, structural, and aerodynamic analyses in Ansys Workbench facilitated a more comprehensive design process, ensuring that all aspects of the propulsion system were optimized in tandem.
- Seamless CAD Integration: The SolidWorks plugin for Ansys enabled smooth geometry updates and rapid design modifications, preserving constraints and load cases across iterations.
SimuTech’s customer support has been very accessible and helpful answering all our technical questions. We’re grateful for their assistance in solving what is a large-scale, complex problem.
Peter O’Regan, PhD
Electromagnetics Engineer, MagLev Aero
Ansys Tools for Electric Propulsion Simulation
MagLev Aero gained access to these powerful simulation tools through the Ansys Startup Program, which provides emerging companies with cost-effective access to industry-leading engineering software. This program was instrumental in enabling MagLev Aero to leverage high-fidelity simulations despite being a small startup with limited resources. By participating in the program, MagLev Aero was able to accelerate product development, validate their electric propulsion design elements early in the process, and compete on a level playing field with larger, more established companies.
- Ansys Maxwell enabled MagLev Aero to optimize their electric propulsion system, providing detailed insights into electromagnetic behavior.
- Ansys Fluent allowed them to simulate aerodynamic performance, accurately capturing flow phenomena that were previously undetected with low-fidelity tools.
- Ansys Mechanical facilitated structural and modal analysis, ensuring that designs met strength and durability requirements.
- Ansys Workbench provided an integrated environment where different physics analyses could be coupled, enabling a holistic approach to system simulation.
SimuTech Group Support
Throughout the implementation process, SimuTech Group provided invaluable support, helping the MagLev Aero team set up complex simulation cases, troubleshoot issues, and leverage Ansys tools effectively. SimuTech’s responsive and knowledgeable team ensured that MagLev Aero could maximize the value of their simulation investment, offering mentorship and technical assistance tailored to their needs.
Conclusion
By partnering with SimuTech Group and adopting Ansys simulation tools, MagLev Aero has overcome critical design challenges and positioned itself for success in the electric aviation industry. The combination of advanced simulation capabilities and expert support has enabled the company to refine its electric propulsion technology efficiently and cost-effectively. As MagLev Aero continues to innovate, its collaboration with SimuTech Group will remain a key factor in driving the future of electric flight.
Powering the Future of Electric Propulsion with Simulation
At SimuTech Group, we help innovators like MagLev Aero push the boundaries of technology with advanced Ansys simulation tools. From optimizing complex propulsion systems to integrating multiphysics analysis, our expertise ensures your designs are accurate, efficient, and ready for real-world performance. Accelerate your path to success, and contact us today!
