CFD engineering services

EnCata provides computational fluid dynamics (CFD) services, including fluid flow simulation, structural and thermal analysis. CFD simulations are required for performing virtual experiments and updating the design before physical prototyping.

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CFD simulation for in-depth understanding of complex systems

Computerized fluid dynamics numerically reproduces what is happening with a real system under investigation. If such a system is simple and one needs to clarify a simple hypothesis, sometimes it is easier and faster to manufacture several real-life prototypes and do the testing.

However, in most cases, the systems which have to be developed are complex and their behavior can not be understood without deep insights on what is happening with temperatures, deformations, how gas velocities are distributed in systems with time, how different mechanisms and physics are interlinked and influence each other. Sometimes it is not possible to physically reproduce required extreme testing conditions, and sometimes virtual testing is much cheaper compared to real-life experiments. In such a case, the only feasible way to proceed is to create a numerical model with a sufficiently deep description of a real system i.e., describing on a computer all necessary processes and properties that need to be understood to design fully functional and optimized products. The Digital model has to provide adequate accuracy, i.e., the validity of the digital model has to be confirmed by real-world testing and verification.

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate


Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

Computational fluid dynamics modeling at EnCata

Computational flow dynamics, which includes Thermodynamics & Heat Transfer Analysis, Structural & Thermal Analysis, is a more elaborated, compared to FEA, computational approach which is used by EnCata’s engineers. While FEA is routinely used by all mechanical engineers, CFD techniques are more specialized and require a deeper understanding of methodology, panel methods in computational fluid dynamics, post-processing, and skills in CFD software. For this reason, we have at EnCata a dedicated simulation group of engineers dealing with CFD projects. In most cases, our own in-house computational resources suffice for such calculations; if necessary, we employ research supercomputers of our partners.

Mechanical Engineering

EnCata helps develop products, which exist in real life and work in various environments. Principles of computational fluid dynamics help be sure that products are functional and safe. Our engineers carry out industrial structures analysis and heat transfer simulation in SolidWorks and other CFD software.

mechanical engineering DFM

Enclosure Design

The enclosure is one of the most common objects for mechanical design. We prefer to work on enclosure design holistically.Heat transfer simulation is more efficient and insightful compared to 1D thermal calculations or 2D heat transfer finite element analysis in Matlab. It helps mechanical designers to understand the system better and prevent the overheating of electronics.

FEA and CFD simulations

Proof-of-Concept Prototyping

The proof-of-concept stage is a good start for new product development. The design of a proof-of-concept prototype is not a simple task, as it can seem at first glance. The key point here is prioritizing functions to be cost-effective. The POC prototype could be a good addition to fluid dynamics simulation.

Custom electronics design

Reverse Engineering (RE)

Using RE gives obvious benefits for any product design company. Since you are not reinventing the wheel during the design stage, you are both saving time and reducing costs. Fluid flow simulation could support RE and provide a better understanding of the system under review.

Firmware development

Feasibility Studies

It is important to understand what benefits new product features will give your business, as well as how this will affect the financial performance. Our engineers could conduct a technical analysis of competitors. Meanwhile, our product design consultants will calculate the preliminary financial indicators, so you can make informed decisions.

Product R&D

The use of computational fluid dynamics (CFD) when testing hypotheses and searching for non-standard solutions allows you to get new information about the object of research much faster. CFD flow analysis is used as a tool for fluid flow simulation and thermo-structural analysis.

Fluid flow modeling make the difference

Computational fluid analysis provides the data for cost-effective design, usage, and maintenance. It helps determine the optimal power of pumps and fans. Industrial structure loads could be optimized by using various CFD techniques.

This leads to a reduction in energy and raw materials' consumption.The computational fluid analysis also reduces risks of redesign and overengineering thanks to experimental data that could be collected almost online by thermodynamics and mechanics simulation.

System Optimization And Computational Fluid Dynamics Applications

Computational fluid dynamics in CFD software and CAD, like Solidworks, can be applied in a vast range of cases and scenarios. Here are just a couple of cases in EnCata where it would have been impossible to develop high-quality products without using CFD.
To optimize the fan blades experimentally, one would need to manufacture and test fans for multiple different blade curvature parameters, which is very expensive. Instead, we have chosen to employ CFD, which allows substituting real-life experiments with a parametric model. The developed model has been validated to ensure the new blade design indeed provides the best performance.

The shape of new blade profiles is described with three new parameters (angles), which allow describing significantly more different blade geometries compared to the approach used to design the fan with the initial blade design. The best new blade shape has then been obtained with help from an optimization tool that automatically obtains the optimal blade configuration by calculating the fan efficiency for different blade geometries. The new optimal blade shape made it possible to get rid of negative pressure zones with the stagnant flow on the pressure side of a blade. This increased the aerodynamic efficiency of the blade from 84% to 92%.

EnCata had to develop a rotary exhaust device for the removal of welding fumes from the working area. During development, in order to ensure maximum performance and norms-compliance of the whole device, it was necessary to make sure that the design of the exhaust socket allowed the minimum airflow to meet the requirements for flow rate at the distance from the socket, according to ISO 15012-2. A computational model of the basic socket structure was prepared, and virtual tests were carried out according to the ISO 15012-2 method using CFD modeling.

Thus, the basic shape of the hood was changed to a new one, requiring a lower minimum airflow rate to achieve the required speeds according to the standard. This modification made it possible to increase the efficiency of the welding aerosol extraction process i.e., improve the performance of the product, without creating intermediate prototypes in metal. Also, with the help of CFD modeling, the aerodynamic characteristic of the PVU was used, which is necessary to coordinate the operation of mobile filter ventilation units to which this device is connected to. 

Within another project, EnCata had to improve the aerodynamic efficiency of a radial fan. Clearly, the efficiency of a fan significantly depends on the blade shape. The blade shape for a given fan was chosen based on the experimental curves of the blade profile, which were taken from the classical fan’s design handbooks. The handbooks rely on the experimental dependencies of fans versus three-blade parameters (inlet and outlet angle, blade radius). More complicated blade shapes, which can not be described with these three parameters, were, therefore, not taken into account in the initial design of the fan that needed to be improved at EnCata.

Product Development Technology Stack

PCBA design

PCB board design: Analog, digital, optical, and RF design
Board layout: mixed signal / high speed / high layer count
Flex-PCB design

Battery management icon

Battery management systems (BMS)
AC/DC and DC/DC design for high battery life

Electronic circuit design and schematic capture
Design for manufacturability/testability (DFM/DFT)

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wireless interfaces design

Wireless systems:  Bluetooth® (BT) & LBE,  Wi-Fi/WLAN (802.11), RFID, NFC

Custom electronics design

STM 32,  NXP chips, Nordic chips, Texas Instruments (TI)
8/16/32 bit MCU development

Arduino family
Raspberry family

Cellular: 2G, 3G, 4G, GSM, GPRS
GPS / Beidou /
NB-IoT,  LTE Cat-M


PID controllers
Physical algorithms development

FPGA design

FPGA development
RTL coding and FPGA simulations, synthesis, place and route

ico IC design

IC design & Power electronics
Invertors and solar power management

interfaces electronics

Interfaces: USB, SPI/SSP, I2C, LVDS, RS232/485, SD/SDHC/MMC, Ethernet, PoE, 1-Wire, CAN, I2S, AC97

Engagement Models

We focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

Some hardware Projects we delivered

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

FAQ related to Product development

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?

EnCata works with both fixed term and agile contracts.

What should I do now that I've approached you with my project idea?

1. Once you have approached us with the project, we conclude the NDA and send the information to the Sales Manager for further evaluation and project planning.
2. The Sales Manager or Sales Engineer will contact you to clarify your goals, requirements and tasks to accomplish. This process is very close to business analysis. When the details are agreed with you, a cost estimate and a quotation are prepared.
3. If you accept the quotation, we will prepare a Technical design specification to document scope of work and requirements and conclude an agreement.
4. After we've signed the agreements, we'll assign you a Project Manager who will gather a project team and report on the project progress.

Can you provide me with a certification of competence?

EnCata employs around 30 engineers with Master's and PhD degrees in electrical and industrial design, mechanical engineering, prototyping and manufacturing from European universities. Each employee is an expert in his or her field.

What level of training do your specialists have?

The majority of specialists are of middle or senior levels. Their range of influence is broad enough to encompass the entire new product lifecycle. Our specialists resolve legal and certification difficulties during the concept stage, optimize production costs during the 3D model development process and create necessary documentation for firmware support. Juniors make up only 15% of the team. They constantly upgrade their qualifications under the supervision of seniors.

Is it possible for us to cooperate with EnCata’s team?

EnCata is always willing to work with its client. We have everything we need to create a collaborative site. Both parties can work on the project simultaneously. The Customer, for instance, and his/ her team designs the electronics while we work on the enclosure. When teams work together to achieve a fantastic result, it is always a win scenario.

Is it possible to discuss the project with your technical team?

EnCata’s team is always willing to discuss all the necessary details about the project proposed. Our full-fledged team of professionals will interrogate you until both parties are satisfied with the procedures necessary to complete the job.

Can EnCata facilitate mass production?

It certainly can. For any product, EnCata creates a design documentation package and a process documentation package that is suited to the production. It should be noted, however, that the technologists at the customer's chosen plant may make changes or impose their own requirements on the documentation design. EnCata, in turn, makes it easier for the client and the technologist to communicate. EnCata does not mass produce, although it can undertake small-scale production at the request of customers.

Do you sign NDAs?

Yes. As a highly professional design and engineering firm, we make sure that all discussions with our clients and all information regarding your invention, idea and other proprietary information are kept confidential.

Patent or Develop first?

We follow a LEAN approach in product and business development and thus we strongly recommend patent filings only after you are  at least part-way through development. This is because patenting is expensive and early patents can already become obsolete or irrelevant later in the development phase. Typically, EnCata's work generates many patentable opportunities for our clients  and the best strategy is to file patents at TRL-7, i.e. when early beta prototype is ready and when a startup is ready to start batch production and marketing.There is, however, another strategy, which is to use provisional patents which can be loose and are not to be disclosed to the public for 18 months. These are much less expensive and time consuming, generally costing below $500.

EnCata will always sign a Non-Disclosure Agreement and keep your intellectual property confidential during the development phase and then we can recommend several third-party patent attorneys when the time is right.

Does EnCata outsource electronics services?

Our in-house professionals handle almost all electronics work, including interface design, protocol development, communication design, schematic design, PCB Design, Firmware design and battery management. If the Customer requires a service that Encata does not supply, we have partners that can meet that need.

Do you write program code, either software or firmware?

We certainly do. EnCata employs electronics specialists who deal with low-level firmware. We also have experts on staff who can implement high-level software code.

Are there hardware engineers in your team?

EnCata employs 12 mechanical and industrial designers and 10 electrical engineers with experience in hardware and firmware. Our team consists of middle and senior level engineers, who have 5+ years of field expertise and have already completed more than 300 projects.

Can EnCata help me with fundraising?

We do indeed help with fundraising through our large business network. However, we typically recommend startups to our partner VCs after we have done some work for the startup and learned more about the team and their core technology. This feedback and recommendation is of great value to all of the friendly VCs as it saves them much time and effort for due diligence.

Have a project to do? Reach out to EnCata team

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