Avoid risks of thermal failures, work with the leader in thermal
Technologies
Expert Thermal works with the world’s top tech companies to guide the mechanical hardware design of electronics products of all types, through all phases – from concept, to development, to manufacturing.
Your Trusted Thermal Design Experts
From Concept to Validation – We Engineer Thermal Systems That Perform
Expert Thermal delivers advanced analysis and design solutions for high-power electronics, consumer devices, and industrial systems.
Using first-order physics, CFD, and system-level modeling, we predict, optimize, and validate cooling performance to improve reliability, efficiency, and manufacturability.
Prevent Product Development Obstacles With Thermal Design
Staring thermal design at the conceptual stage not only prevents product release delays and ensures product reliability but also enables the product development team to accommodate changes dictated by new product marketing requirements like the unanticipated higher performance components releases. Chip companies often don’t reveal their roadmap in time, especially to new customers, and may release new chips with higher performance. If the thermal design occurs early in the process, the impact of last-minute changes can be easily assessed and accommodated with no risk. Our thermal engineers will create the required thermal models and conduct the required thermal prototype testing early in the product development process to allow for any potential changes to the product requirements and/or product changes. These validated thermal models we create for your product enable the rapid evaluation of the thermal performance of the product with new changes and modifications of the thermal management solution, including the airflow management system (fans, fan speed, vents, baffles, etc.), heatsinks and thermal interface material (TIM).
Multi-Scale Thermal Modeling
Physics-Based Modeling Across Every Level of the Product
Our engineers apply a combination of first-order analytical modeling, computational fluid dynamics (CFD), and system-level simulations to accurately predict heat flow, pressure drop, and temperature distribution in complex systems.
This multi-scale approach ensures design efficiency from chip to system, eliminating costly late-stage redesigns.
Capabilities:
• First-order analytical models for quick performance prediction
• Detailed 3D CFD using Ansys Icepak, FloEFD, or equivalent tools
• Transient and steady-state analyses for real operating conditions
• Coupled electro-thermal and thermal-structural simulations
• Parametric optimization for fan curves, fin density, and flow uniformity.
Applications:
• AI accelerators, GPUs, and high-power ASICs
• Cameras, optical sensors, and consumer electronics
• Automotive and EV power systems
• Industrial and telecom enclosures.
System-Level Design and Energy Optimization
Optimizing Energy and Water Efficiency from the Start
We extend beyond component cooling to model full thermal networks, fluid loops, and airflow systems.
Our models evaluate energy use, water consumption, and cooling effectiveness, enabling informed design decisions that reduce both PUE and WUE.
Services Include:
• First-order system energy and water models
• Flow network analysis for liquid and air loops
• Fan and pump performance optimization
• Heat exchanger and cold-plate design optimization
• Design-for-Energy-Efficiency (DFEE) evaluation
Thermal Design and Validation
From Simulation to Reality
We convert analysis results into robust thermal designs that balance performance, cost, and manufacturability.
Our design process includes mechanical layout, material selection, and validation testing to verify thermal performance and ensure compliance with safety and reliability standards.
Deliverables:
• Detailed thermal and mechanical design drawings
• Bill of Materials (BOM) and specifications
• Prototype test plans and validation reports
• Design-for-Manufacturing (DFM) and Design-for-Reliability (DFR) reviews
• Failure-mode analysis and corrective design recommendations.
Expertise Across Industries
Thermal Engineering Experience That Spans Technologies
For more than two decades, our team has provided solutions to the world’s top innovators in electronics, energy, and mobility. We have worked on systems ranging from high-density data-center hardware to advanced consumer and EV applications.
Sectors:
• AI and HPC computing systems
• Data center infrastructure
• EV computers, cameras, and power systems
• Consumer electronics and optical products
• Industrial automation and robotics
Contact Us Today
Ready to evaluate or optimize your next product or cooling system?
Contact us to discuss your project requirements and modeling needs.
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