Case Study: Cincinnati Test Systems achieves $45K cost savings and accelerated leak-test chamber optimization with SimScale CFD

Cincinnati Test Systems used SimScale CFD to optimize a leak test system

Cincinnati Test Systems, a leading designer and manufacturer of standard and custom leak test systems since 1981, needed to validate and optimize accumulation-style leak-test chambers without costly, time-consuming physical prototypes. The main challenge was ensuring reliable air mixing and avoiding low-flow “blind spots” that can hide leaks; to address this, Cincinnati Test Systems turned to SimScale and used SimScale CFD to virtually test chamber airflow and guide design changes.

Using SimScale, CTS prepared cleaned CAD, ran meshes (1.5M then ~8M cells) and executed four steady-state turbulent flow simulations on 96 cores (about 2 hours per run) to compare design variants. The CFD revealed a dead zone between tooling and the part; by adding two fans and repositioning flow blockers the team significantly improved air patterns. SimScale CFD enabled roughly $10,000 saved per iteration (about $45K total reported), faster design cycles, and additional thousands saved in avoided re-manufacturing costs.

Cincinnati Test Systems

Peter Bonyhati

Systems Engineer