Summary
Key results
Pressure drop reduced by 27% on average, from around 100 mbar to below 80 mbar
Validated valve design with limited prototyping and lower material use across size variants
A valve series requiring better flow performance
For the company, the project supported the refresh of an existing industrial valve series and its competitiveness. The key technical requirement was clear: reduce pressure drop in the fully open position from around 100 mbar to below 80 mbar, while keeping the product manufacturable and ready for further development.
In water installations, lower pressure drop means lower flow resistance. This can support more efficient system operation, reduce local energy losses, and potentially lower the load on pumps. For the client, improving this parameter was therefore not only an engineering goal, but also a way to improve the product’s value proposition.
At the same time, client’s internal teams were managing a high project workload. The client needed additional engineering capacity from a partner able to combine flow simulation, CAD design, and practical validation against real measurement data. The work required detailed interpretation of physical phenomena, iterative geometry refinement, and close cooperation with the client’s CAD and simulation teams.
Simulation-led valve geometry optimization
Sii Poland combined flow simulation, CAD design, and prototype-based validation to optimize the valve geometry while limiting the need for physical test iterations. The project started with validation of the baseline simulation model against real flow and pressure measurements from existing products. This gave the team a reliable basis for further optimization work before modifying the 3D design.
Using computational fluid dynamics (CFD), Sii experts analyzed flow behavior inside the valve and iteratively adjusted the internal geometry, including transition areas, flow direction changes, and channel cross-sections. The team first developed and validated the approach on one selected size variant, then applied the methodology across additional variants, reducing the number of iterations as the team transferred lessons to the next variants.
The work was carried out in close cooperation with the client’s CAD and simulation teams. Depending on the project phase, Sii and the client held 1–2 project meetings per week to review geometry changes, simulation results, measurement feedback, and the final target design.
Scope of work included:
- Validating the simulation model against flow and pressure measurements from existing products
- Running iterative CFD simulations in Ansys Fluent to reduce pressure drop
- Updating 3D valve geometry and CAD models in CATIA V5
- Reviewing simulation results and design variants with the client’s CAD and simulation teams
- Preparing partially parametric CAD models that allowed geometry changes within each size variant
- Verifying final design behavior through 3D-printed prototypes and flow tests
Better flow efficiency with lower development risk
With Sii Poland’s support, the company received a validated valve design that met the required pressure-drop threshold and improved flow behavior in the fully open position. The optimized internal geometry reduced local flow resistance, supporting better valve efficiency parameters and strengthening the refreshed product’s competitiveness.
The simulation-led approach also helped limit development risk and physical prototyping effort. By validating the baseline model against real measurements and using iterative virtual optimization before physical testing, the team reduced the need to prototype every design option. Final 3D-printed prototypes were used to confirm correlation between simulation results and real flow performance for the selected geometry.
The project also created a practical basis for further valve development. Sii delivered partially parametric CAD models that allowed geometry changes within each size variant, while the optimization work helped reduce material use across the analyzed variants. With further valve groups planned for optimization, the project gives the client a tested approach for combining simulation, CAD design, and measurement-based validation in future product work.
Key results
- Pressure drop reduced by 27% on average, with results ranging from 20% to 42% depending on the size variant
- Required pressure-drop threshold achieved, from around 100 mbar to below 80 mbar in the fully open position
- Material use reduced across analyzed size variants
- Baseline simulation and final design validated against real flow and pressure measurements
- Physical prototyping limited through simulation-led optimization and final prototype testing
- Partially parametric CAD models prepared to support geometry updates within each size variant
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