Troubleshooting and resolving a new blade server’s overheating challenges in the field Challenge The client’s newly launched server was suffering from overheating following the product’s launch. This problem had not been seen in trials and was causing server down time and reputational damage. The client wanted a retrofittable solution and update to the manufacturing process. Solution CEAD used CFD modelling validated with practical testing to reconfigure the airflow within the server to optimise cooling under all conditions. The final design not only stopped the unit overheat but reduced the number of fans in the server by 40%. Details CEAD’s client had recently launched an updated server model. Following the product launch several server units suffered from overheating issues which had not been observed during the original trial and testing of the product. The overheating issues had resulted in server down time, as well as reputational damage for the client. The client needed a solution which able to be quickly retrofitted to existing units and an updated manufacturing process for new units to resolve this issue. CEAD used CFD modelling to redesign the internal layout of the server to optimise cooling under all operational conditions. This redesign aimed to improve the internal airflow of the unit and ensure that the unit would not overhead in future. The computer models were validated using physical models to ensure that the solution was appropriate and effective. The final design that CEAD handed over to the client not only resolved the overheating issues for the server but also require 40% fewer fans within the unit. This resulted in both lower running and production costs of the unit.