Home › Engineering Consulting Services › Multiphysics Simulation Services
Coupled thermal, fluid, structural, and electrical models solved before tooling
Send your CAD and loads. Get a roadmap to a design that holds. Free.
Single-physics models answer one question at a time. Real equipment heats up, flows, flexes, and carries current all at once, and each effect changes the others. When the physics are split up, teams pick one of two costs.
They add margin to every model to cover what the others might do, and pay for it in weight and cost. Or they find the interaction in test, where heat warps a seal or flow shakes a part loose. Our multiphysics simulation services solve those effects together.
A hot spot, a pressure load, or a current path shows up in the same model as the stress it causes. We link FEA and CFD for coupled thermal structural analysis. We also draw on the depth of our FEA thermal analysis services and heat transfer solutions. You get a design checked against all the physics it will see in service.
✓
Heat that warps parts or loosens seals
Thermal and structural results disagree in test.
✓
Flow that shakes, erodes, or loads structures
Fluid forces never reached the stress model.
✓
Electronics with heat and stress problems
Current, heat, and strain interact on the board.
✓
Separate models that disagree
Each team's answer misses the others' effects.
✓
Margins stacked on margins
Every model adds safety for what it can't see.
✓
Failures nobody can reproduce in one model
The cause sits between two kinds of physics.
Cost you carry
Decision it lets you make
Result
Unit cost
Material & weight
Decision
Solve heat, flow, and stress together, then remove margin you no longer need to stack.
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Result
A lighter, cheaper design that still meets its loads.
Development
Prototypes & testing
Decision
Predict coupled behavior before the build, and go to test to confirm it.
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Result
Fewer prototype loops and shorter test phases.
Tooling
Rework & redesign
Decision
Find the interaction behind the failure and fix the geometry before tooling is cut.
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Result
No redesign after first article; tooling is built once.
After launch
Field failures & warranty
Decision
Model real duty cycles across all the physics, and release with documented margins.
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Result
Fewer field failures and a design you can defend.
01
A design that meets your loads at the lowest total cost, delivered as production-ready CAD and drawings
02
FEA results and margins you review and approve at each gate, before anything moves to prototyping.
03
You own the IP by default, set in your contract.
04
If we missed it in our QC, we fix it. If your supplier can't make the part within three years, or supply dries up, we fix that too.
You send
What we need to start
CAD, native or STEP
Loads and operating conditions, or how the part is used
Material specs or test data, if you have it
Targets: weight, cost, life, or code
Failure history, if a part already failed
→
You get
What you hold at the end
The optimized design: CAD and drawings ready for production
Models and results you reviewed and approved
Documented margins or code compliance
Test correlation, when testing is in scope: a partner lab or yours
A roadmap for what comes next, and a team that stays with you
We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
We review your project scope and the data you have, and screen which physics interact.
Scope, targets, and gates, from where you are to where you need to be.
Coupled FEA and CFD with CAD changes, plus partner-lab tests when needed.
The design, drawings, and models, second-checked in our QMS.
We stand behind the design through production and supply issues.
Our engineers run FEA, CFD, and DFMA as one loop. Flow and heat feed the structural model, and results drive CAD changes. Then cost is checked before tooling, so the design you approve is the design that ships.
Heat, flow, and stress apart
Or stack margins until it does
Tooling and test article paid for
Heat or flow breaks the part
New geometry, new prototype, new test
Which physics interact here
Heat, flow, stress, current
Geometry refined to real margins
Second engineer verifies the model
Build once, to confirm
Every prototype loop you fund is margin lost. Get a free roadmap.
Get Your Free RoadmapAvionics and power boxes checked for heat, vibration, and stress together before qualification test.
Pass the qual test once.
Applications
Avionics
Heat
Vibration
Altitude
Turbine parts, generators, and heat exchangers checked for coupled heat, flow, and stress in service.
Fewer forced outages.
Applications
Turbines
Generators
Heat
Flow
Battery packs, motors, and power electronics modeled for heat, current, and stress in one simulation.
Pass the heat soak once.
Applications
Batteries
Motors
Inverters
Heat Soak
Racks and power gear checked for airflow, heat, and structural loads together at full IT power load.
Run cool at full load.
Applications
Racks
Power Gear
Airflow
Heat
FEA, CFD, CAD, DFMA, and testing under one roof. Engineering is a team sport, and you get the whole team.
One team, every skill.
Under One Roof
FEA
CFD
CAD
DFMA
Testing
Veteran-owned SDVOSB status gives defense and federal buyers a set-aside path to proven engineering.
Verify our SDVOSB status.
Credentials
SDVOSB
VOSB
CAGE 8ZK73
NAICS 541330
Missed something in our QC? We fix it. Supplier can't make the part within three years? We fix that too.
Support for the long run.
We Fix
Our QC Misses
Supplier Gaps
Supply Chain
We price to the value we deliver, not hours logged. You buy a design that works, not more iterations.
Pay for the result only.
Collections
Gold
Platinum
Diamond
When does a design need multiphysics simulation services?
A design needs multiphysics simulation services when one effect changes another and separate models can't see it. Heat changes stress. Flow changes heat and load. Current makes heat. If your parts live with more than one of these, a single-physics model will miss part of the story in service. Watch for five signs. Heat warps parts or loosens seals in test. Fluid forces shake or erode structures. Electronics show heat and stress problems together. Separate models disagree, or every model carries extra margin for what it can't see. NASA's standard for models and simulations asks how far you can trust each model.
Any one of these signs means the cause sits between two models. Solving the physics together removes the stacked margins and finds the real problem. It also gives every team one answer to work from. We review your project scope and loads in a free assessment and tell you which physics interact. If separate models are enough, we say so. Our engineering simulation guide explains the method in more depth.
One-way or two-way coupling: which do I need?
Our multiphysics simulation services use the simplest coupling that answers your question. One-way coupling passes results from one model to the next, such as temperatures from a CFD model into an FEA stress model. It works when the second effect doesn't change the first one in any real way. Pick the wrong coupling and you pay either way. Too simple, and the model misses feedback that drives the failure. Too complex, and run times grow, so fewer design options fit the schedule. Either way, the answer needs checking against test data, as ASME's V&V 20 standard for CFD and heat transfer sets out.
Most thermal stress and pressure load problems are solved one way. Two-way coupling trades results back and forth until both models agree. We use it when effects feed each other. Examples are a flexible part that changes the flow around it, or a heater whose resistance changes with temperature. We run coupled work in ANSYS and other solvers suited to the physics. The free assessment tells you which approach fits.
Can PPS work with our manufacturer or test lab?
Yes. Our multiphysics simulation services work with the shops and test labs you already trust, or with our partner network. Many projects use both. What matters is that one engineering team ties them together, so every party works from the latest design and the latest data. When each vendor reports to you on its own, you become the integrator. Changes travel by email, parts get cut to old drawings, and test results arrive with nobody tasked to act on them. The Defense Department's IPPD Handbook organizes programs around integrated product teams for this reason, with design, build, and test working to one plan.
We manage your builders and test labs inside one engineering loop. We release the design, plan each test to confirm the margins that matter, and correlate the model to the results. If a test shows a miss in our QC, we fix it. NDAs cover every party from the start. You decide how far we take the design, and you own the IP by default, set in your contract.
Who owns the design and the models?
You own the design, the drawings, and the models from your multiphysics simulation services project at delivery. Some firms keep the models, or license them back to you, so every later change sends you back to them. That locks your product to one vendor and makes design reviews harder, because your team can't open the evidence behind the decisions. At PPS, the IP transfers with the solution. Nothing is held back to tie you to us. You receive the native CAD, the drawings, the simulation model files, and the documented results. Your engineers can then check the work, rerun a load case, or hand the package to a supplier or customer.
We sign mutual NDAs before any of your data is shared, and your files stay in our controlled project folders while we work. If your program has export-control or customer data rules, tell us at the start and we will set up the data handling to match them. For defense programs, the State Department ITAR guidance sets the rules we follow.
What happens if a prototype fails in test?
If a prototype fails in test, we find out why and fix the design. Hard engineering carries unknowns on any project: real loads, material lots, and assembly effects never match a model perfectly. With multiphysics simulation services from PPS, you approve the data at each gate. A test result is then checked against predictions you have already seen, not a black box. A failure in test is data. It shows which assumption was wrong: a load, a material property, or a boundary condition. That data improves the model and the design.
When testing is in scope, we plan the test to confirm the margins that matter most. Then we correlate the model to the results, following ASME verification and validation practice. If the miss was ours, because something slipped through our QC review, we fix it. If the test uncovers a condition nobody knew about, we scope the change with you and update the roadmap. Either way, you get a clear answer and a path to a design that holds.
How are multiphysics simulation services priced?
We price multiphysics simulation services to the value they deliver, not the hours we log. Hourly billing rewards extra iterations, so the cheapest quote often becomes the most expensive project once tooling, rework, and field failures show up. Our incentive is to get the design right the first time. We engage by fit, not as a ladder. Gold (from $35K): you have one project and need help with it. Platinum (from $15K/mo): you have recurring work at a steady rhythm. Diamond (from $800K/yr): you have a long development program, often multi-year.
Gold is never required, and some clients start at Platinum or Diamond. These are starting points, not quotes; your roadmap sets the price. We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment. Our engineering consultant pricing page explains how each collection works in more detail.
Not sure which physics interact? Send the model. Free roadmap.
Send your model and loads. We review your project scope in a free assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.
