Advanced Thermal Systems
Our Company
A Global Reference in Advanced Thermal Engineering
Who We Are
Thermal Design Solutions (TDS) is an engineering company founded in 2019 by Dr. Fadil Ayad, specialising in the design and simulation of advanced thermal systems.
With over 20 years of experience in the automotive thermal industry, our team has contributed to major OEM and Tier-1 projects, covering everything from system architecture and R&D to simulation, durability, and industrialisation.
We have supported leading companies in the automotive, energy conversion, and refrigeration sectors, delivering innovative and reliable solutions built on deep technical expertise and proprietary tools.
At TDS, customer satisfaction is our top priority. We go the extra mile to meet our commitments, adapt to each client’s needs, and deliver results with precision, transparency, and integrity.
Vision & Mission
To lead in advanced thermal engineering by delivering innovative, energy-efficient, and sustainable solutions across mobility, energy, and refrigeration sectors.
At TDS, we combine simulation software, thermodynamic expertise, and real-world engineering to
- Design and optimise high-performance thermal systems.
- Enable smarter, more sustainable energy and cooling solutions.
- Support our clients from concept to prototype — with precision and flexibility.
- Reduce environmental impact through low-GWP, PFAS-free refrigerants such as R744 and R290.
- Accelerate innovation with proprietary tools like HEXsim® and EvapSkin™.
Going The Extra Mile
Why Work With Us
Working with TDS means choosing a partner who takes your thermal challenges as seriously as you do.
We bring more than expertise — we bring reliability, agility, and a real commitment to making your project a success.
- Proven track record with leading OEMs and Tier-1 suppliers
- Advanced in-house simulation tools (HEXsim®, EvapSkin™)
- Full-cycle support: from concept to validated prototypes
- Strong R&D mindset combined with industrial pragmatism
- Customer-first culture: we deliver what we promise — no shortcuts
Whether you need smart simulation, technical advice, or complete thermal system design, we’ll go the extra mile — and back it up with results.
Our Design SolutionsCorporate Social Responsibility (RSE)
Sustainability
At Thermal Design Solutions, sustainability is not a slogan — it’s a design principle.
We believe that engineering must serve both performance and the planet. That’s why we integrate environmental responsibility into the heart of our thermal solutions.
- We promote the use of natural refrigerants with low global warming potential (GWP) and PFAS-free alternatives, supporting the transition to more sustainable refrigeration and HVAC systems.
- We develop waste heat recovery technologies that enhance the energy efficiency of thermodynamic systems — helping clients reduce energy losses, cut emissions, and unlock untapped value.
- We support the development of renewable energy by contributing to advanced thermal energy storage systems, including Carnot battery architectures, to improve flexibility and resilience in low-carbon energy systems.
Through our projects, proprietary tools, and partnerships, we aim to create solutions that are not only technically sound but environmentally responsible — today and for the long term.
We see sustainability not as a constraint but as a source of innovation—and we’re proud to help our clients build a cleaner, brighter future.
Our Design SolutionsSolutions
CONCEPT TO PRODUCTION
HEX Development & Sizing
Developing radiators, condensers, evaporators, R744 gas coolers, CACs, chillers, and oil coolers for automotive and industrial applications.
VEHICLE COOLING
FCM Design & Development
Cooling modules that integrate seamlessly. Balancing thermal efficiency and packaging constraints.
RECOGNISED EXPERTS
Fin & Tube Design
Optimised fin and tube designs that maximise performance while respecting pressure drop and manufacturing constraints.
ADAPTIVE SOLUTIONS
CFD Analysis
We use Computational Fluid Dynamics when the physical problem can’t be handled by our in-house 1D/2D HEX simulation (HEXsim) and to optimise heat-transfer surface geometries.
STRESS TESTING
FEA Analysis
Finite Element Analysis ensures mechanical integrity and durability before production.
Lower CO₂
Waste Heat Recovery & Energy Storage
Our techno-economic studies ensure solutions are not only technically feasible but also cost-effective and sustainable.
automotive & stationary
Refrigeration Systems
Specialising in heat pump systems using natural refrigerants such as R744, R290 and other hydrocarbons.
Our founder
Dr Fadil Ayad
Founder and Managing Director of Thermal Design Solutions
Fadil Ayad founded TDS in 2019 and brings more than twenty years of experience in automotive thermal engineering. His expertise covers heat exchangers, cooling systems and heat pumps, including CO₂ (R744) applications.
He spent twelve years in advanced development and project acquisition at Delphi Thermal Luxembourg and subsequently Mahle Behr Luxembourg. He holds a PhD from Université de Lorraine, where his research focused on modelling and experimentally characterising a mini-channel evaporator for R744 automotive air conditioning.
At TDS, he applies this experience to the design, sizing and validation of customers' thermal solutions. He has also taught heat exchangers and thermodynamics at the University of Luxembourg since 2014.
References
We have partnered with:
- OEMs & Tier-1 suppliers — Brose, Schaeffler, Innerio, AVL.
- Industrial leaders in refrigeration, HVAC, and energy storage.
- Technology innovators in ultra-low refrigeration and electric vehicle thermal management.
Key Achievements:
- Development of a powerful heat exchanger simulation tool, HEXsim®.
- Key contributors in various awarded programs in heat exchangers and front-end cooling modules.
- Development of benchmark louvered fin and dimpled tube geometries.
- Key contributors in developing new products in the automotive market (WCAC, WCOND, R744 air-cooled gas-cooler, R744 Liquid Gas cooler, and R744 evaporator).
- Front-end cooling module performance specification for VW Group.
Partners
We work with manufacturing specialists in aluminium brazing, stamping, machining, and additive manufacturing, as well as testing facilities for full durability and performance verification. Academic collaborations strengthen our R&D capabilities.
Thermal Design Solutions