Case Studies

Scaling chemical reactions from the lab to pilot or production requires a detailed understanding of the physical system, which frequently involves heat transfer, mass transfer, reaction kinetics, and fluid flow. This case study illustrates how multiphysics simulations can support design decisions involved in scaling up chemical reactors.

Veryst Engineering developed proof-of-concept models for a device for harvesting energy from constant low speed ocean floor currents in order to power ocean sensors.

Shear thickening and jamming in dense particulate suspensions can lead to undesirable processing inefficiencies and failure modes across a variety of product applications, including inkjet printer nozzles, medical autoinjectors, and porous filtration systems.  In this case study, Veryst simulated the flow of a dense suspension through a syringe needle to evaluate the conditions that lead to shear jamming.

Knowledge of thin film mechanical properties is important for device operation, reliability, and simulation. Veryst measured the elastic modulus of a low stress silicon nitride thin film using nanoindentation and validated the technique with atomic force microscopy.

The design of compression springs is tied to their intended function and the acceptable levels of deformation and stress that the spring can withstand. Veryst designed and evaluated a standalone simulation application to capture important qualities, such as spring rate, natural frequencies, and estimated fatigue life, for both helical and conical compression springs.

Cavitation, the formation and collapse of vapor bubbles in a liquid due to local pressure drops, can limit performance and reliability in medical devices, energy systems, and process equipment—causing unwanted wear, vibration, and efficiency loss. In this case study, we applied high-fidelity multiphase computational fluid dynamics simulations to capture the unsteady dynamics of cavitation in confined geometries and demonstrate how simulation can guide the development of safer, more efficient, and longer-lasting products and systems.

The physics of droplet formation during dripping, jetting, and atomization governs the accuracy and consistency of a wide array of fluid dispensing and spray technologies. In this case study, we apply high-fidelity multiphase flow simulations to capture the full droplet formation cycle and reveal mechanisms that control necking, breakup, and satellite drop formation. The results demonstrate how simulation can guide the design of more precise, efficient, and reliable fluid dispensing and spray technologies.

Arrays of impinging fluid jets are an effective design solution for applications requiring large heat transfer rates. This case study demonstrates the ability of computational fluid dynamics (CFD) to predict heat transfer coefficient distributions and guide design choices to improve cooling uniformity.

Vial filling—the precise transfer of liquids into vials under controlled conditions—is a common process step in pharmaceutical, diagnostic, and laboratory applications, where product quality and regulatory compliance demand exceptional consistency and reliability. This case study compares two filling strategies using moving and fixed inlet nozzles, demonstrating how controlling the distance between the nozzle and the liquid surface can produce clean fills or, conversely, lead to undesirable outcomes such as dripping, splashing, and air entrainment. These results provide practical guidance for engineers seeking to refine filling protocols, minimize waste, and ensure consistently reliable production.