Mechanical engineering services for custom thermal management systems
Delivering comprehensive thermal management solutions from concept to aftercare, we combine precision mechanical engineering services, advanced manufacturing, rigorous testing, and dedicated support.
Expert mechanical engineering services
Calatherm’s thermodynamic engineering team is equipped with advanced Computer-Aided Engineering (CAE) tools, enabling precise modelling, simulation, and analysis for each thermal management solution.
With capabilities in 1D/3D CFD (Computational Fluid Dynamics), structural FEA (Finite Element Analysis) simulation, we ensure that our designs achieve optimal heat transfer, airflow, and energy recovery.
Modular heating and cooling design
We utilise modular concepts that can be easily customised and scaled based on vehicle requirements. This allows for efficient packaging within limited space, ensuring heating and cooling systems fit a variety of vehicle types from commercial trucks to specialised electric vehicles.
Full thermal solution system simulation
Through precise 3D CFD simulations, we optimise airflow distribution across heat exchangers and radiators, reducing pressure drops and improving overall system efficiency. Our designs focus on maximising cooling performance while minimising energy usage.
Fully tested thermal solutions for real world applications
Our comprehensive in-house testing capabilities ensure that our thermal systems are ready for real world applications from day one, seamlessly integrating into your operations to reduce cost and downtime.
Fully tested thermal solutions for real world applications
Our comprehensive in-house testing capabilities ensure that our thermal systems are ready for real world applications from day one, seamlessly integrating into your operations to reduce cost and downtime.
Environmental testing
Our on-site environmental chambers replicate real-world operating conditions, including temperature testing up to +50°C, with humidity control and solar load capabilities up to 1,200 W/m² to simulate the harshest environments your vehicles may encounter.
Thermal performance testing
We conduct detailed thermal performance testing to assess heat transfer, fluid flow, and system efficiency. This testing helps to verify the effectiveness of radiators, HVAC units, and heat recovery systems under different operational conditions, ensuring optimal cooling and heating for every application.
Vibration and shock testing
We perform vibration and shock testing to helps us identify any potential weaknesses and confirm that our thermal systems are built to withstand the demands of continuous operation in vehicles like construction machinery, commercial fleets, and off-highway applications.
Pressure and leak testing
Our pressure and leak testing processes ensure that every coolant circuit, HVAC system, and heat exchanger is secure, airtight, and ready to handle the fluid pressures associated with heavy-duty thermal management.
Electromagnetic compatibility (EMC) testing
For electric and hybrid vehicles, where required we carry out EMC testing to verify that our thermal components are shielded from electromagnetic interference. This ensures compatibility with other vehicle electronics and systems, preventing any disruption or malfunction caused by electromagnetic disturbances.
Functional testing and calibration
Each thermal system undergoes functional testing to verify that it meets design specifications and customer requirements. Systems are calibrated for precise temperature control, ensuring that HVAC units, heat recovery systems, and cooling packs operate effectively and efficiently under all conditions.
Validation for industry standards and compliance
Our testing procedures include validation against industry standards and regulations, such as safety, fire resistance, and environmental compliance. This ensures that every product not only performs reliably but also meets the necessary legal and safety requirements for its application.
Contact us
Whether you need advice on a new project, guidance on system integration, or help with selecting the right component for your power transmission application, calatherm’s team are here to support you.