Creating & Modeling Filter Pleats


The PleatGeo module enables the modeling of flat as well as cylindrical filter pleats with freely varying pleat form. One of the main applications of flat filter pleats (flat filters, cassette filters) is air filtration, e.g. for cabin air filters. Here, the filter medium of the pleat can consist of several porous layers, which have different permeability values (material permeabilities). To ensure the stability of the filter pleats, it is also possible to model support structures and support meshes in PleatGeo. These functionalities allow to quickly design novel filters for different user requirements.

However, PleatGeo is also capable of producing cylindrically pleated filter elements (round filters, lamella filters). Cylindrical pleated filter elements are widely used as they provide a large filter area in limited space, with the well-known benefits of low pressure drop and high filter capacity. In order to optimize the performance of pleated filters, expensive and time-consuming measurements of filtration-relevant parameters are often necessary. In GeoDict, digital filter structures can be efficiently generated as well as simulated to calculate the filter performance. Subsequently, only the promising prototypes are produced and measured on the test bench.

In the modelling step, the pleat pack inner and outer diameter, inner radius at pleat valley and tip, the pleat height as well as the pleat count can be specified to customize  the individually generated pleat structure.

In addition, PleatGeo can model both classic cylindrical filter pleats and M-shaped filter pleats. M-shaped filter pleats offer the advantage that not all pleats have the same pleat height and thus additional filter area is available with the same or reduced pressure drop.

Compared to the methodologies of Computer-Aided-Design (CAD), our 3d image-based approach works completely automatic and requires no manual meshing steps before the simulations can run. The simulation is calculated quickly and precisely by the efficient and memory-optimized numerical solvers. Thus, it is possible to calculate parameter studies automatically in a short time. Furthermore, our cloud solutions can further increase efficiency by running a large number of parallel simulations at the same time. This innovative simulation approach facilitates the development and testing of improved filter pleat structures and significantly reduces time to market.

Examples of Applications

PleatGeo Features in Overview

  • Modeling flat and cylindrical filter pleats
  • Modeling pleated filters with / without support structures and support meshes
  • Individual customization options for pleat structures
  • Filter performance can be calculated without expensive and time-consuming measurements
  • Fully automated 3D-based approach without manual meshing
  • Fast and accurate simulations thanks to efficient and memory-optimized numerical solvers
  • Efficient, automated simulation of parameter studies is possible

Additional modules needed?

Modules Applications
GeoDict Base  Includes the basic functionality of GeoDict [necessary]
ImportGeo-CAD For complete filter with housinge:  Import of STL or OBJ files of the housing and convert them to voxel data for the simulation  [optional]
FilterDict FilterDict-Element: Filter efficiency and filter life time [necessary]
FlowDict Computes flow fields as well as the pressure drops or mean velocities [necessary]
GridGeo For honeycomb structure models: generation of unresolved porous media  [optional]
ExportGeo-CAD Export of 3D structures modeled with PleatGeo as surface triangulation (*.stl) for CAD programs [optional]
ExportGeo-Abaqus /
Export of 3D structures modeled with PleatGeo as simulations with Fluent / Abaqus [optional]