Tech Talk | September 04, 2025 | 11:00 AM EST
Presenter – Pratik Korgaonkar
In this session, Pritique demonstrated how Simcenter FLOEFD for NX can simulate headlight condensation and thermal flow in automotive systems. He highlighted how environmental conditions like cold, humid weather combined with internal heating from headlights or the engine bay often cause condensation inside the lens — a challenge for both performance and safety.
Attendees explored how FLOEFD integrates seamlessly with NX CAD, enabling engineers to set up, simulate, and visualize airflow, thermal transfer, and condensation effects in a realistic, time-dependent environment.
Topics To Be Covered
Pritique began by explaining the physics of condensation: when the external lens surface is colder than the humid interior, moisture accumulates. He shared prevention techniques such as proper sealing, vent cap installation, and silica gel packs, along with repair methods like resealing or upgrading housings.
Key Takeaway: Understanding condensation behavior early helps engineers design more reliable lighting systems.
The session explained that a Design BOM is CAD-centric, created by designers in the CAD tool, and focuses on geometry, models, and structure. The Engineering BOM, on the other hand, includes everything needed to build the product—mechanical, electrical, software, documents, even non-geometric items like sealants or packaging.
Key Takeaway: FLOEFD integrates smoothly with NX, making thermal-fluid simulation part of the design process.
Using transient analysis, Pritique showed how headlights respond over time. Starting in a cold, humid environment, condensation formed inside the lens. As the LEDs and filaments turned on, the simulation tracked heating, evaporation, and moisture dissipation.
Key Takeaway: FLOEFD predicts not only when condensation occurs but also how it clears, improving design validation.
The demo highlighted:
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Mesh refinement for complex geometries like filaments and reflectors.
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Visualization of airflow, temperature gradients, and radiation rays inside the headlight.
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Film growth and evaporation timelines showing condensation forming and disappearing around 1200 seconds, when headlights activated.
Key Takeaway: Engineers can capture real-world behaviors—heat, moisture, and airflow—in a virtual test environment.
What challenges do you face in thermal and condensation simulations—environmental conditions, materials, or test protocols? Share your thoughts with the community.
Missed the live session? Catch the recording and learn how Simcenter FLOEFD for NX can help predict and prevent headlight condensation in your designs.
Our Tech Talk series continues with deep dives into advanced SIMCENTER capabilities and best practices that help you stay ahead in modern manufacturing.
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