Malungelo Luzipho
Engineering Project & Design Portfolio

I'm an Aeronautical Engineer with extensive expertise in numerical simulations, specializing in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and Electromagnetic Interference & Compatibility (EMI/EMC). My background combines deep technical knowledge with practical experience in modeling, analysing, and optimizing complex physical systems, as well as system automation, thus enabling me to deliver high-precision engineering solutions across aerospace, automotive, electronics, and related industries.

I received my Bachelor's (BEng.) in Aeronautical Engineering in June 2021 from the Nanjing University of Aeronautics & Astronautics (NUAA), China, and I'm on the verge of completing my Master's (MSc.) in Numerical Simulations in Engineering from the Technical University of Madrid, Spain. This website provides an overview of some of the engineering projects that I have led and executed in my career.

Worked With

Selected Work

Drop-test Simulation

A virtual analysis used to evaluate the behaviour of an electronic device when dropped from a set of specific heights using Finite Element Analysis (FEA). Tools used:

  1. Ansys SpaceClaim
  2. Ansys Discovery
  3. Ansys Mechanical (LS-DYNA)
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CFD Analysis of a Hypersonic Missile

Numerical simulation of high-speed airflow (Mach 5 and above) around a missile to study the aerodynamic behavior, shock wave formation, heat transfer, and pressure distribution. Tools used:

  1. Ansys SpaceClaim
  2. Ansys FLUENT
  3. OpenFOAM
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Toroid Inductor Magnetic Field Simulation

EM simulation of a toroid's magnetic field (magnetostatic) in which the steady-state magnetic behavior of a tranformer device when subjected to a constant current was analysed. The simulation calculated the magnetic flux density, field intensity, and distribution within and around the toroid core. It helps assess core material performance, magnetic confinement, and efficiency. Tools used:

  1. Ansys Maxwell
  2. MS Excel
  3. Ansys SpaceClaim
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2D CFD Simulation of a Shockwave

This CFD simulation of a shock wave propagation from the exit of a tunnel modelled the high-speed flow behavior as a pressure wave exits a confined space into open air. The simulation captures shock formation, expansion fans, and interaction with ambient air, providing insights into pressure distribution, wave speed, and potential structural impacts. It's useful for analyzing blast effects, exhaust dynamics, or emergency ventilation scenarios. Tools used:

  1. Ansys FLUENT
  2. Ansys SpaceClaim
contribute dev

FSI Simulations For A Wind Loading Analysis

This project focused on wind loading analysis of 5G radio boxes using a combined approach of Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). CFD simulations were employed to model airflow and determine pressure distributions around the radio boxes under various wind conditions. The resulting wind loads were then applied in FEA to evaluate the structural response, including stresses, deformations, and potential failure points. This integrated analysis ensured reliable performance and structural integrity of the 5G equipment under realistic environmental conditions. Tools used:

  1. Ansys FLUENT
  2. Ansys Mechanical
  3. Ansys SpaceClaim
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Parametric Thermal Analysis on Heatsink

This project involved a thermal performance parametric analysis of 2 heatsinks using Finite Element Analysis (FEA). The study evaluated the heatsink’s ability to dissipate heat under various operating conditions, focusing on temperature distribution, airflow behavior, and thermal resistance. Simulations were conducted to optimize fin geometry and material selection, ensuring efficient heat dissipation and maintaining component temperatures within safe operating limits. The results guided design improvements for enhanced thermal management in chosen electronic systems. Tools used:

  1. Ansys Mechanical
  2. Ansys SpaceClaim
contribute dev

2-Slit Waveguide Simulation

The two-slit waveguide simulation using Ansys HFSS aimed to analyze the electromagnetic wave propagation and interference patterns resulting from a dual-aperture configuration in a rectangular waveguide. A TE10 mode was excited at the waveguide’s input port, and the geometry featured two narrow slits positioned symmetrically along the broad wall to mimic a classic double-slit setup. HFSS was used to solve the full-wave Maxwell equations, capturing the resulting field distribution beyond the slits. The simulation revealed characteristic interference fringes, demonstrating constructive and destructive interference zones, validating wave behavior in confined structures. This setup is useful for exploring wave diffraction phenomena in high-frequency RF or microwave systems. Tools used:

  1. Ansys HFSS
contribute dev

Aerodynamic Analysis of a Surveillance UAV

This project involved the aerodynamic assessment of a surveillance unmanned aerial vehicle (UAV) to optimize its performance, stability, and efficiency during flight. Using computational fluid dynamics (CFD) and relevant aerodynamic theory, the analysis evaluates key parameters such as lift, drag, pressure distribution, and flow behavior around the UAV's airframe and control surfaces. The study aimed to identify design improvements that enhance endurance, maneuverability, and operational effectiveness, making the UAV more suitable for long-duration surveillance missions. Tools used:

  1. Ansys Fluent
  2. Ansys SpaceClaim
contribute dev

Modal Analysis of a Satellite Bus Structure

This project focused on performing a modal analysis of a satellite bus structure to evaluate its dynamic behavior under launch and in-orbit conditions. Using Finite Element Analysis (FEA), the structure was modeled to determine its natural frequencies and corresponding mode shapes. The analysis helped identify potential resonance issues and guided design modifications to ensure structural integrity and performance during launch vibrations and operational maneuvers. The results provided critical input for both structural optimization and vibration isolation strategies in the satellite’s overall design lifecycle. Tools used:

  1. Ansys Mechanical
  2. Ansys SpaceClaim
contribute dev

Aerodynamic Analysis of a F1 Car Rear Wing

This project involved simulating airflow around a Formula 1 rear wing to evaluate its aerodynamic performance. Using CFD tools, the study focused on analyzing downforce generation, drag characteristics, and flow separation behavior under various operating conditions. The rear wing geometry was assessed in terms of pressure distribution, wake structure, and efficiency metrics such as lift-to-drag ratio. The goal was to gain insights into how design features influence aerodynamic stability and overall vehicle performance at high speeds. Tools used:

  1. Ansys Fluent
  2. Ansys Mechanical
  3. Ansys SpaceClaim
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Academic Research Work


Undergraduate Thesis: Investigation On Aircraft Aerodynamics in Gusty Inflow Conditions.

Consulting Services

I support your product development process by applying state of the art, industry standard numerical simulation methods.

For my projects, I use commercial CAE codes such as ANSYS, StarCCM+, OpenFOAM, among others. I offer my expertise to solve fluid flow, heat transfer, structural mechanics, electromagnetics, fluid-structure interaction (FSI), and radiative transfer.

cae

Why Me

I apply a systems engineering approach to aeronautical design, integrating FEA and CFD into streamlined, simulation-driven workflows. With expertise in structural analysis, aerodynamic design and optimisation, electronics cooling, and low-level programming, I deliver tightly integrated, high-performance solutions across mechanical, electronic, and software domains.

Research Focus

My research interests focus on the application of high-fidelity multiphysics simulations to address complex engineering challenges in the aerospace, automotive, electronics, and energy industries. I'm interested in the use of CFD and FEA to model turbulent flow, conjugate heat transfer, thermo-mechanical stresses, fatigue, and fluid-structure interaction under transient and thermally driven conditions, in addition to electromagnetic simulations for high-frequency systems, electronics cooling, and EMI/EMC analysis, key concerns in compact, high-performance devices. My intended approach is one that would emphasize validated simulation workflows, including mesh refinement, sensitivity analyses, and correlation with experimental data to ensure predictive accuracy and engineering reliability. These interests are strongly aligned with the simulation-driven R&D efforts of modern engineering organizations, where virtual prototyping is critical to accelerating innovation, reducing physical testing, and optimizing system-level performance.

Training

I provide comprehensive training in the use of industry-standard simulation and modeling tools, including Ansys SpaceClaim for CAD and geometry preparation, Ansys Fluent for computational fluid dynamics (CFD) and heat transfer simulations, Ansys Maxwell for low-frequency electromagnetic field analysis, Ansys HFSS for high-frequency electromagnetic simulations and antenna design, and Ansys Mechanical for structural, thermal, and modal analysis. In addition, I offer instruction in OpenFOAM, an open-source CFD toolbox widely used for custom fluid dynamics applications. My training sessions cover both fundamental concepts and advanced simulation workflows, emphasizing real-world application, best practices in model setup and meshing, solver settings, post-processing, and interpretation of results. Whether for academic research, industrial design validation, or certification readiness, my goal is to equip learners with the skills and confidence to apply these tools effectively and independently across a wide range of engineering problems.

Software Tool Expertise

StarCCM+ Ansys Altair Matlab Solidworks Catia Python OpenFOAM HTML C++ GitHub

My Services

  1. Green Tick

    Flow Simulation (CFD)

    Use of commercial Navier-Stokes solvers such as Ansys-FLUENT, OpenFOAM, & StarCCM+ to simulate complex flows patterns including heat transfer, multiphase, moving geometries, and more.
  2. Green Tick

    Structural Analysis (FEA)

    Use of commercial FEA solvers such as Ansys Mechanical to solve statics and dynamics, vibrations, rotor dynamics, life cycle fatigue, fracture mechanics, thermal analysis, and more.
  3. Green Tick

    Consulting

    With expertise in Computer-Aided Engineering (CAE), I offer simulation-driven consulting services that help to bring complex engineering designs to life and optimize them.
  4. Green Tick

    Engineering Design

    Comprehensive engineering design services with a strong focus on Computer-Aided Design (CAD) for complex mechanical and aerospace systems, from detailed CAD model preparation to system-level simulation.
  5. Green Tick

    Electromagnetic Simulation

    High-fidelity electromagnetic simulations for analyzing and mitigating Electromagnetic Interference (EMI) and ensuring electromagnetic compatibility (EMC), i.e., modeling wave propagation and antenna performance.
  6. Green Tick

    Multiphysics Simulation

    Conduction of accurate analysis of coupled behaviors such as fluid-structure interaction, electro-thermal effects, and thermal-mechanical stress across aerospace, electronics, automotive, and related industries.

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Let's talk about your project

As an Aeronautical Engineer specializing in CAE, with expertise in CFD, FEA, and multiphysics simulations, I help solve complex engineering challenges through high-precision modeling and simulation-driven design.

I'm also an open-source website and mobile application developer, and in my spare time, I enjoy freelance coding.

Malungelo Luzipho