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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

An efficient second-order adaptive procedure for inserting CAD geometries into hexahedral meshes using volume fractions

Here, this paper is concerned with inserting three-dimensional computer-aided design (CAD) geometries into meshes composed of hexahedral elements using a volume fraction representation. An adaptive procedure for doing so is presented. The procedure consists of two steps. The first step performs spatial acceleration using a k-d tree. The second step involves subdividing individual hexahedra in an adaptive mesh refinement (AMR)-like fashion and approximating the CAD geometry linearly (as a plane) at the finest subdivision. The procedure requires only two geometric queries from a CAD kernel: determining whether or not a queried spatial coordinate is inside or outside the CAD geometry and determining the closest point on the CAD geometry’s surface from a given spatial coordinate. We prove that the procedure is second-order accurate for sufficiently smooth geometries and sufficiently refined background meshes. We demonstrate the expected order of accuracy is achieved with several verification tests and illustrate the procedure’s effectiveness for several exemplar CAD geometries.

Adaptive↗
DOE OSTI2024

Monte Carlo Simulation with CAD Interface for Calculation of 3D Maps of Residual Dose (CRADA)

Objective: To develop an easy-to-use software application to predict and mitigate radiation effects in research environment, space instruments, nuclear plants and medical facilities and help nonproliferation and national security efforts. Tech-X will develop standalone software libraries and command-line tools for ( 1) translating CAD into tessellated surfaces and tetrahedral meshes in GDML (for Geant4 and MARS 15), ROOT (for MARS 15) and HDF5 (for compact representation and for the visualization) formats, (2) healing CAD geometries to make them suitable for Monte Carlo simulations; (3) creating uniform and variable Cartesian and cylindrical meshes for detailed scoring; and ( 4) efficient Monte Carlo navigation in CAD geometries. JLAB will finish automation of simulations of residual dose in CAD geometries and integrate Tech-X software into Geant4 and MARS15. Finally, Tech-X will develop a Graphical User Interface to set up and heal CAD geometries, create input files, run and visualize simulations for residual dose. This application will run on local desktops, local and remote clusters and supercomputers and will be made available through public clouds, such as Amazon Web Services.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2025

An open-source hybrid unstructured mesh - CAD fusion multiphysics analysis workflow in SALAMANDER

Plasma facing components in fusion devices will endure extreme neutron and heat fluxes. To facilitate their design using simulation tools, the open-source Fusion Module, Fusion ENergy Integrated multiphys-X (FENIX) framework is being developed to model these components with a high-fidelity multi-physics multi-dimensional approach. It can iteratively resolve couplings between all the physics at play, from neutron radiation, to thermomechanics, to near-wall plasma dynamics. This framework is based on the Multiphysics Object Oriented Simulation Environment (MOOSE), which is developed by a collaboration of US National Laboratories since 2008, for advanced nuclear, geomechanics simulations and other applications. FENIX couples numerous simulation tools, including OpenMC, the Tritium Migration Analysis Program v8, the NekRS CFD software, and most MOOSE modules. For the coupling of radiation transport and other physics, FENIX supports a hybrid workflow between Computer Assisted Design (CAD) and unstructured mesh geometries. The CAD can be generated from skinning the unstructured mesh, to enable a coarse geometry for efficient particle transport, but still resolving the local material compositions and temperature gradients. Neutron transport is performed using DAGMC on the CAD, and Cardinal, integrated in FENIX, maps tallied quantities, such as the heat deposition or the tritium generation rates, from a tally volumetric mesh to the other physics’ unstructured mesh. This coupling was exercised on a simplified tokamak geometry, coupling neutron transport with the heat conduction equation, and on a monoblock divertor problem, coupling additionally with tritium migration. Mesh convergence studies highlight the importance of the mapping conservativeness. Coupling with thermo-mechanics is further enabled by the generalization of the approach to moving meshes. The presentation will include these coupled analysis as well as an update on status of the FENIX framework.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Laboratory Upgrade Point Absorber (LUPA) CAD Files

The Laboratory Upgrade Point Absorber (LUPA) is an open-source wave energy converter designed and tested by Oregon State University. The computer-aided design (CAD) files are provided here in two forms: the original SOLIDWORKS (2021) model as "LUPA SOLIDWORKS.zip" and as a STEP file "LUPA-A1000.step". The bill of materials is provided as an Excel file with assemblies (LUPA-Axxx), part numbers (LUPA-Axxx-Pyyy), part descriptions, manufacturers, and manufacturer part numbers. This comprehensive CAD model represents LUPA as it was deployed in Fall 2022 testing at the O.H. Hinsdale Wave Research Laboratory. The mass properties including mass, center of gravity, and moments of inertia have been overridden for some parts and assemblies to match the physical device properties as determined from experiments. This appears as "overridden by user" when viewing mass properties in SOLIDWORKS. The LUPA-A1000.SLDASM file from the LUPA SOLIDWORKS.zip folder is the topmost assembly, open this file to see the entire model as one assembly. See "PMEC Page", "OpenEI Wiki Page", and the "Signature Project Page" resources below for more information on LUPA.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Investigation of CAD-based Geometry Workflows for Multiphysics Fusion Problems Using OpenMC and MOOSE

Fusion system designs are complex and require intricate and accurate meshes to be properly modeled. In this study, we investigate the use of CAD-based geometry workflows in fusion systems multiphysics problems. A simplified tokamak was introduced and modeled in CAD using a multiphysics coupling of OpenMC Monte Carlo transport and MOOSE heat conduction. The meshed geometry was prepared using direct accelerated geometry Monte Carlo (DAGMC) for particle transport, and a volumetric mesh was also prepared to be used in MOOSE and to tally OpenMC results. Cardinal was used to run OpenMC Monte Carlo particle transport within MOOSE framework. The heat source distribution and tritium production were calculated in OpenMC. The data transfer system was used to transfer heat source and temperature distribution between OpenMC and MOOSE. Two computational studies related to mesh refinement were performed: (1) refining the DAGMC and volumetric meshes used for tallying results and solving heat conduction and (2) only refining the DAGMC particle transport mesh. The refinement of the tally mesh has a much larger effect on the runtime compared to the refinement of the DAGMC particle transport surface mesh.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

CAD-VAE: Leveraging Correlation-Aware Latents for Comprehensive Fair Disentanglement

While deep generative models have significantly advanced representation learning, they may inherit or amplify biases and fairness issues by encoding sensitive attributes alongside predictive features. Enforcing strict independence in disentanglement is often unrealistic when target and sensitive factors are naturally correlated. To address this challenge, we propose CAD-VAE(Correlation-Aware Disentangled VAE), which introduces a correlated latent code to capture the information shared between the target and sensitive attributes. Given this correlated latent, our method effectively separates over-lapping factors without extra domain knowledge by directly minimizing the conditional mutual information between target and sensitive codes. A relevance-driven optimization strategy refines the correlated code by efficiently capturing essential correlated features and eliminating redundancy. Extensive experiments on benchmark datasets demonstrate that CAD-VAE produces fairer representations, realistic counterfactuals, and improved fairness-aware image editing.

Ma, Chenrui [University of California Irvine]↗
DOE OSTI2024

SOFAST CAD Layout Tool Overview and User Guide (Document Version 1.0)

Concentrating solar mirrors need to have correct geometry to accurately focus sunlight onto a receiver. SOFAST is a tool created at Sandia National Laboratories which measures a mirror’s surface normal at a dense sampling of points, enabling evaluation of a given mirror’s expected performance. SOFAST supports general mirrors, including concentrating solar heliostats, troughs, and dishes. The examples presented in this report predominantly focus on heliostats.

14 SOLAR ENERGY↗
DOE OSTI2024

CAD-based Energy & Cost Models Prove Affordable Net Zero Energy Performance for WonderWindows + 24" On-center Framing

Windows are thermally the “weakest link” in the building envelope. Increasing the thermal resistance of windows can make buildings more energy efficient and reduce the cost of electricity needed for conditioning the building. The proper design and placement of framing can also help to reduce the thermal bridging that occurs near the window frame area. This study investigates the energy performance of multi-pane acrylic windows fitting 24" on-center framing. Initial parametric analysis is done for a single zone accessory dwelling unit (ADU). Then, an energy model was developed for three types of wood-framed buildings: townhomes, stacked flats and hotels. A whole building energy simulation is performed for each of these building types in hot-humid Houston, mixed-humid New York, and cold-humid Minneapolis climates. The results show up to a 39% reduction in heating, ventilation, and air-conditioning (HVAC) related electricity consumption for the cold climate compared to the Base case which has window and wall properties based on ASHRAE standard 90.1 2019. In the hot climate, a modest increase in electricity consumption was seen due to an increase in cooling electricity demand. The ADU achieved Net Zero Energy performance in all 3 Climate Zones despite having the highest exterior surface area-to-floor area ratio: the ADU also had the highest PV kW to floor area ratio compared to the other multi-story building types. The townhomes, hotel and stacked flats respectively met 73, 52 and 57 % of electrical use in Houston, 71, 48 and 56 % in New York, and 63, 40 and 53 % in Minneapolis from energy produced by rooftop solar. If 400 W solar panels are used instead of 320 W panel used for energy simulation, it is estimated that in the townhomes, hotel and stacked flats rooftop solar can meet 91, 65 and 71 % of electrical use in Houston; 89, 60 and 70% in New York, and 79, 50 and 66 % in Minneapolis. A preliminary evaluation of cost shows that such superior performance can potentially be achieved at less first cost with this 24"on-center solution than conventional construction. All the building types at the three locations used for simulation had net energy use intensity under 20 kBtu/sf/year with 320 W solar panel and under 17 kBtu/sf/year with 400 W solar panel. Further tailoring of building envelope R-values and window solar heat gain to particular Climate Zone locations for each building type shows promise in reducing the HVAC electricity use that comprises almost half of building energy use.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Enabling the broader adoption of fusion simulation on complex geometry

This project addressed a key barrier to advanced fusion and nuclear simulation: the difficulty of performing high-fidelity Monte Carlo neutronics directly on complex, real-world CAD geometry. Traditional workflows require engineers to rebuild CAD models as simplified constructive solid geometry, a time-consuming and error-prone process that limits design iteration and broader adoption of simulation tools. The goal of this Phase I SBIR was to make CAD-based neutronics practical, accessible, and robust for industrial and research users. During the project, Coreform significantly enhanced the Direct Accelerated Geometry Monte Carlo (DAGMC) workflow and fully integrated it into Coreform Cubit as a first-class capability. Major achievements include optimized material assignment and surface meshing workflows, substantial performance improvements to geometry imprinting and preparation, native export of DAGMC models, and new visualization tools to support OpenMC source definition and lost-particle debugging. Coreform also expanded Cubit’s capabilities as a full OpenMC preprocessor, including the ability to convert OpenMC constructive solid geometry models back into CAD for visualization, multiphysics coupling, and debugging. In collaboration with Argonne National Laboratory, the project delivered comprehensive new DAGMC documentation and training materials, transforming DAGMC from a research-oriented tool into a production-ready workflow. Results were disseminated through tutorials, conference training, and multiple well-attended webinars demonstrating integrated CAD-based neutronics and multiphysics workflows. Overall, this project demonstrated that high-fidelity Monte Carlo simulations can be performed directly on complex CAD geometry, reducing setup time, improving usability, and enabling faster, more informed design decisions for fusion and nuclear energy systems.

42 ENGINEERING↗
DOE OSTI2024

Development of a Method for Shape Optimization for a Gas Turbine Fuel Injector Design Using Metal-Additive Manufacturing

Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗
DOE OSTI2024

Testing the Activation Analysis for Fusion in OpenMC

OpenMC is a community-developed Monte Carlo neutron and photon transport simulation code. It can perform fission simulations such as fixed-source, k-eigenvalue, and subcritical multiplication calculations on models built using either a constructive solid geometry or CAD representation. To explore the use of OpenMC for fusion activation analysis, a detailed model of the Fusion Neutronics Science Facility (FNSF) was first developed for comparisons against an existing SERPENT model. A 90-degree model of FNSF in Standard-Triangle-Language (STL) CAD format was converted to Constructive Solid Geometry (CSG) using each code's built-in functions, and the geometries were validated by ensuring no cells overlapped and no particles were lost during simulations. The neutron fluxes were calculated and compared for multiple components close to the plasma. The results show differences mostly below 1% in fluxes and averaged 8% for activity and decay heat. Here, the work described in this study tests the CAD-based geometry using the DagMC toolkit in OpenMC and compares the activation analysis of OpenMC to SERPENT code.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗