Case Study: Fairchild Controls achieves quieter, faster EFV environmental control fan development with ANSYS CFX

Defense Contractor Designs Safer Environmental Control System for Marine Corps New Amphibious Vehicle Using CFX Software

Fairchild Controls was contracted to redesign the environmental control system (ECS) for the U.S. Marine Corps’ Expeditionary Fighting Vehicle (EFV) to meet strict size, airflow, pressure and noise constraints within a 14-month schedule. Working against a fixed installation envelope and requirements to produce 1,000 cfm with a 6.5 in. water pressure rise at under 4,500 RPM while keeping sound levels tolerable, Fairchild turned to ANSYS and its CFX software (CFX‑BladeGen, CFX‑TurboGrid, CFX‑TASCflow) to accelerate design and analysis.

Using ANSYS CFX tools, Fairchild designed a slower mixed‑flow fan, evaluated dozens of 3‑D virtual designs in weeks, exported the chosen geometry to CAD, and machined an in‑house prototype that matched simulation results. ANSYS-enabled modeling cut the design cycle by months, let Fairchild build the fan more cheaply than buying components, and produced a unit that met cooling targets and operated at about 85 dB; the program delivered required units within the 14‑month window and is moving into low‑rate initial production.

Fairchild Controls

Jeff Hutchison

Principle Engineer