THERMAL ENGINEERING SERVICES
Thermal Engineering and Mechanical Design
TDS develops heat exchangers and thermal systems for automotive and industrial applications. We combine sizing, simulation, and mechanical design to support your projects through vehicle integration and prototyping.
About Us
Thermal Design Solutions (TDS) is a Luxembourg-based provider of thermal engineering services and custom heat exchanger design for the automotive, industrial, rail, and HVAC sectors. Founded in 2019 by Dr. Fadil Ayad, we combine advanced thermal-fluid science expertise with decades of hands-on experience in product development, 1D/2D/3D thermal-hydraulic simulations, and manufacturing support.
ABOUT TDS
We deliver award-winning automotive thermal systems, high-efficiency refrigeration units, and innovative waste heat recovery solutions for leading OEMs and Tier-1 suppliers. From early feasibility studies to series production, TDS offers full-lifecycle support to help customers achieve optimal thermal performance, meet cost targets, and comply with environmental standards.
Our Services
Award-winning heat exchangers & thermal systems for leading OEMs and Tier-1 suppliers
- Various types of high-performance and durable single and two-phase flow heat exchangers.
- Benchmark fin and tube designs optimised for various applications
- High-performance front-end cooling module
- High-efficiency R744 and R290 refrigeration systems.
- Advanced waste heat recovery solutions integrating Carnot batteries, ORC, and Brayton cycles.
From early feasibility studies to full production, TDS supports the entire lifecycle, ensuring designs achieve optimal thermal performance, cost targets, and environmental compliance.
What We Do
Core Expertise
Vehicle thermal management systems
Architecture, Simulation, Sizing.
Heat Exchangers
Concept, Simulation, Sizing, Durability, Manufacturability.
Simulation Tool
HEXsim®, a licensed software for compact heat exchangers.
Driving Future Mobility
Electrification & Sustainability
As industries shift towards electrification and sustainability, TDS is actively supporting:
- Efficient EV heat pump systems using natural refrigerants (R744, R290) with optional ejector integration.
- Immersion cooling for batteries, enabling ultra-fast charging (>5C, >15 kW).
- Smart cockpit thermal concepts, combining heat pumps with surface heating for energy savings and comfort.
- Next-generation front-end cooling modules, designed for low noise, aerodynamic efficiency, and extended EV range.
Thermal Design Solutions
Pushing Boundaries
Innovating Energy Systems with Natural Fluids for a Cleaner Future
Proven Innovation
Multiple patented heat exchanger designs, benchmark fin/tube geometries, and advanced R744/R290 system expertise implemented in award-winning projects.
FIND OUT MOREGlobal Partnerships
Why Choose TDS?
Strong collaboration with OEMs, Tier-1 suppliers, leading manufacturing partners, and universities to deliver cutting-edge, durable, and efficient solutions.
FIND OUT MORE
Complete Platform of Services
Your Partner in Innovation
helping industry move towards electrification and sustainability.
Through our ecosystem of academic and industrial partners, TDS offers a complete platform of services:
- Heat exchanger and thermal system design.
- Prototyping, manufacturing, and OEM-certified testing.
- Training, consultancy, and business support (RFQ, PDP, PPAP, APQP).
Whether optimising an existing design or developing the next generation of thermal systems, TDS is your trusted partner in sustainable innovation.
OUR SERVICESThermal System Specialists
Full Lifecycle Expertise
From concept design and simulation to manufacturing support and production launch, TDS covers every stage of thermal system development.