Manufacturing
Sintavia Pioneering Lightweight Aerospace Component Design With NVIDIA Accelerated Computing
Objective
Sintavia, a digital aerospace component manufacturer, is redefining thermal management systems through simulation-driven design. Their mission: To deliver highly efficient, lightweight heat exchangers for the aerospace and defense industry—in unprecedented timelines. Traditional workflows, constrained by manual processes and limited compute resources, couldn’t keep pace with the complexity of advanced geometries and stringent performance requirements.
By adopting NVIDIA RTX PRO™ 6000 Blackwell Workstation Edition GPUs in high-performance workstations and NVIDIA data center GPUs in high-performance computing (HPC) clusters, Sintavia unlocked new levels of design freedom and eliminated bottlenecks in its vertically integrated workflow. This breakthrough was powered by GPU-accelerated software applications from nTop and Siemens, which are NVIDIA CUDA™ enabled to deliver faster computational fluid dynamics (CFD) simulations and design workflows.
Customer
Use Case
Simulation / Modeling / Design
Key Takeaways
- GPU acceleration delivered over 11x faster results for Siemens Simcenter STAR-CCM+ conjugate heat transfer simulations compared to traditional CPU processing (7 minutes on a single NVIDIA RTX PRO 6000 GPU vs 88 minutes on a 24-core CPU) for a 30-million cell, 300-iteration run).
- The new lightweight, single-piece heat exchanger design realized a 30% reduction in weight and 20% improvement in thermal efficiency for aerospace applications, validated by CT scanning and in-house testing.
- Sintavia achieved a delivery timeline of just two weeks for a fully optimized, 3D-printed aerospace heat exchanger, enabled by GPU-accelerated simulation and design workflows.
Setting New Standards With Local GPU-Powered Workflows
For years, developing complex thermodynamic components relied on manual CAD and iterative prototyping—a slow, resource-intensive process. More advanced designs meant scaling complexity: as models grew to hundreds of millions of cells, compute limitations stalled progress.
“Before, we were constrained by compute,” said Jose Troitino, principal design engineer at Sintavia, “Large simulations could take days—even weeks. With NVIDIA Blackwell GPUs, we’ve cut runtimes dramatically and scaled to models we never thought possible.”
Sintavia broke this cycle by embracing a simulation-driven approach. Their workflow now integrates CFD in Siemens Simcenter STAR-CCM+ and implicit modeling in nTop, powered by local NVIDIA Accelerated Computing platforms. Building on the previous-generation NVIDIA GPU platform, Sintavia upgraded to the latest NVIDIA Blackwell architecture to unlock next‑level performance on increasingly large, compute- and memory‑intensive workloads. This breakthrough enables rapid iteration without sacrificing fidelity or safety.
nTop implicit modeling accelerated by NVIDIA’s latest Blackwell GPU architecture
Sintavia used nTop to create a heat exchanger mesh optimized for the RTX PRO 6000 Blackwell GPU, utilizing 82.6 GB of the full 96 GB of RAM. The mesh contained over 30 million elements.
“We’re not just designing heat exchangers, we’re pioneering a new era of thermal management with solutions that are lighter, stronger, and engineered for the most demanding environments.”
Jose Troitino
Principal Design Engineer at Sintavia
Bringing HPC-Class Simulation to the Local Workstation
The NVIDIA RTX PRO 6000 Blackwell Workstation Edition features 96 GB of ultra-fast GDDR7 memory and 24,064 CUDA cores, enabling Simcenter STAR-CCM+ conjugate heat transfer simulations that once required HPC clusters and were constrained by limited CPU compute resources to now run efficiently on a single workstation.
Sintavia monitored iteration solver times on a steady-state simulation run to convergence, creating a consistent benchmark for comparing hardware.
Simcenter STAR‑CCM+ CFD Performance: NVIDIA RTX PRO 6000 vs. CPUs
Case Study: Two Weeks to Breakthrough in Heat Exchanger Development
When tasked with delivering a next-generation heat exchanger for a major aerospace client, Sintavia leveraged its simulation-driven workflow, powered by NVIDIA GPUs, to compress a months-long effort into two weeks. As a result:
- Accelerated simulations with GPU compute delivered more than 11x faster results than CPU processing for Simcenter STAR-CCM+ workloads.
- Sintavia delivered a fully optimized, 3D-printed heat exchanger in just two weeks—powered by GPU-accelerated simulation.
- Lightweight, single-piece designs achieved about 30% weight reduction and 20% thermal efficiency gains for aerospace platforms.
- The company validated integrity through in-house CT scanning and downstream thermal/flow testing.
In Sintavia’s tests, the NVIDIA Blackwell GPU ran a 30 million-cell Simcenter STAR-CCM+ conjugate heat transfer simulation with over 300 iterations in just 7 minutes, compared to 88 minutes on a 24-core AMD 7965WX CPU—a speedup of over 11x. With 96 GB of GPU memory, engineers can run full multi‑physics models in memory, reducing infrastructure complexity and accelerating design exploration. Workloads that once required 128 or even 256 CPU cores can now be executed locally, bringing HPC-class CFD and thermal analysis directly to the workstation.
Sintavia’s 3D-printed heat exchanger core, fabricated as a single-piece unibody for aerospace applications.
A New Era of Simulation-Driven Design and Manufacturing
Sintavia’s success story demonstrates how the latest NVIDIA Blackwell architecture GPUs and integrated workflows are transforming traditional manufacturing. The company’s commitment is clear: accelerate innovation using latest GPU-accelerated computing platforms to deliver cutting-edge thermal solutions for aerospace and defense. By integrating innovative design tools, accelerated computing, and advanced manufacturing, they've set a new benchmark for speed, efficiency, and innovation in aerospace thermal management.
Transform your engineering workflows with NVIDIA accelerated computing