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Discuss your next thermal project with our specialists in automotive thermal management, waste heat recovery systems, heat exchanger design, simulation, and manufacturing support.

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Simulation Tools

Simulation Tools

HEXsim & EVAPSKIN

TOOLS
PROPRIETARY SOFTWARE

Simulation Tools

Advanced simulation is at the core of Thermal Design Solutions’ engineering approach. Our proprietary tools are validated by extensive test data and enable us to predict performance with high accuracy, shorten development cycles, and reduce prototyping costs.

HEXsim heat exchanger simulation software — Configuration screen
HEAT EXCHANGER SIMULATION

HEXsim

HEXsim is TDS’s in-house software for sizing and rating compact heat exchangers across automotive and industrial applications. It handles both single-phase and two-phase flow with a wide variety of fluids, including synthetic and natural refrigerants (R1234yf, R134a, R744, R290).

Key Features

  • Models all automotive HEX types and many compact industrial designs
  • Simulates fin, tube, and plate geometries:
      Fin: Plain, Louvered, Offset Strip, Wavy
    • Tube: Flat, Multiport, Inner Fin, Dimpled
    • Plate: Chevron, Inner Fin
  • Predicts thermal-hydraulic performance and pressure drop
  • Incorporates both state-of-the-art theory and empirical correlations validated by vast test data
  • Extremely user-friendly interface for rapid iteration

Advantages

  • Enables design trade-off analysis (performance vs. pressure drop)
  • Reduces reliance on costly prototype testing
  • Optimises designs for real-world manufacturing constraints

The ultimate tool for rapid, accurate HEX sizing and rating.

HEXsim operating conditions — fluid properties and calculation setup
HEXsim tube and fin geometry configuration screen
HEXsim pass arrangement and tube configuration screen
A TDS PRODUCT

HEXsim

HEXsim is the dedicated product identity for TDS’s proprietary heat exchanger simulation software. Built on years of validated thermal-hydraulic research, HEXsim delivers rapid, accurate sizing and rating of compact heat exchangers for automotive and industrial applications.

From single-phase liquid-to-air radiators to complex two-phase evaporators and condensers, HEXsim supports the full range of HEX types with an extremely user-friendly interface designed for engineering professionals.

Capabilities

  • Fin, tube, and plate geometry modelling across all standard HEX configurations
  • Single-phase and two-phase flow simulation with natural and synthetic refrigerants
  • Thermal-hydraulic performance and pressure drop prediction
  • Design trade-off analysis optimised for real-world manufacturing constraints
Discover HEXsim
HEXsim product icon
HEXsim — heat exchanger simulator

heat exchanger simulator

HEXsim configuration screen — heat exchanger simulation setup
EVAPORATOR SIMULATION

EVAPSKIN

EVAPSKIN specialises in evaporator performance simulation, particularly for refrigeration systems equipped with skin-type evaporators.

Key Features

  • Predicts heat and mass transfer in compact evaporators
  • Models refrigerant-side boiling and air-side condensation
  • Accounts for condensate retention and drainage geometry effects
  • Enables wet-condition thermal performance optimisation

Applications

  • Household refrigerators and freezers
  • Medical refrigerators and ultra-freezers
SYSTEM-LEVEL SIMULATION

Thermodynamic System Simulation

Beyond individual components, our tools support system-level thermal simulations including:

Thermodynamic Systems

Heat pump systems for automotive and stationary applications, ORC, Brayton cycles, and Carnot batteries.

Front-End Cooling Module Performance

Coupled airflow and HEX sizing simulation for Cooling & Radiator Front Modules.

Example Applications

  • Sizing and performance evaluation of a Carnot battery with or without waste heat recovery
  • Optimising vehicle front-end cooling modules to find an optimal trade-off between thermal performance, energy saving, and noise reduction

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