EnCata runs FEA and CFD simulations early in product development to spot heat, stress, and airflow issues before they turn into hardware problems. A wrong assumption can mean a failed prototype or a tool that needs to be recut, so we treat simulation as part of the development process, not as a one-off report.
We use simulations to answer engineering questions before build, test, tooling, or scale-up. Based on model assumptions and material data, we identify what may fail, why it may fail, and how the design should change. When there is no prototype for validation, we clearly state that limitation.
We translate results into practical decisions: geometry, ribs, vents, insulation, wall thickness, material, or flow path changes.
We model the product with realistic loads, heat sources, flow rates, contacts, constraints, and material properties.
We define what the product must prove: strength, cooling, airflow, pressure, vibration, efficiency, deformation, or safety.
We prepare geometry, mesh the model, run simulations, compare variants, and analyze critical zones.
One team owns CAD, simulation, and prototyping within the same project. That means no handoff gaps between vendors who fail to sync.
Send us your CAD file and the failure you're worried about. We'll tell you honestly whether FEA/CFD will answer it before you commit budget.
You know what you pay for. We break down what's behind every stage.
Access to up to 72 processors enables large-scale FEA, CFD, thermal, and multiphysics simulations with heavier models, larger meshes, faster scenario comparison, and shorter iteration cycles.
Rather than treating simulation as a separate report, we connect it with CAD, electronics, mechanics, prototyping, and production decisions.
We translate the findings into an easy-to-comprehend report with clear, required steps.
For 15 years, we have been refining our internal processes and expanding our engineering stack to solve complex hardware, industrial, and product development problems. The list below is not exhaustive, and you can always specify what you need for your project in the contact form.
Deep domain understanding increases the success rate of your product.
A simulation result can look precise while the model behind it is wrong. The real value comes from defining the right physical question, choosing the right material data, and setting conditions close to how the product will actually operate.
That is why EnCata treats simulations as engineering decision tools, not visual proof.
Wrong material assumptions can make a simulation look accurate while hiding the real failure mode.
Loads, heat sources, airflow, pressure, contact, and constraints define whether the model reflects real use.
We remove heavy CAD geometry to avoid overloading the process while preserving the physics.
Work that highlights the incredible technologies, solutions, and products EnCata developed
EnCata carried out advanced CFD and FEA simulations to help an industrial manufacturer analyze heat and gas flow in a copper smelting furnace. The insights revealed inefficiencies, guided geometry improvements, and supported modernization across TRL 1–9.
total compute time for simulation runs
to get the final validated model
EnCata engineered and manufactured a custom ATEX explosion-proof industrial vacuum cleaner for sugar dust removal. Our services included mechanical engineering, DFM, FEA simulations, and integration into the mill’s central cleaning system.
were produced and commissioned
dust processing capacity
A startup developed a novel ceramic gas burner capturing IR radiation for higher efficiency. EnCata validated the concept with industrial computer simulations and CFD modeling, proving 84.9% efficiency after 300+ experiments.
experiments were run on the computer cluster
were considered in the multiparametric simulations model
This custom-built system extracts up to 50 liters of water per day from air in hot, dry regions. Developed to meet a specific customer's needs, it showcases EnCata’s full-cycle expertise in thermal design, electronics, firmware, and prototyping. All IP belongs to the customer.
The energy consumption of the system per liter of water
Instead of 6 - it took for us to develop and manufacture the TRL-7 prototypes
EnCata engineered and manufactured a custom ATEX-compliant explosion-proof baghouse for a sugar processing plant. The system filters 32,000 m³/h of dusty air, integrates smart PLC controls, and meets strict IIIB explosion safety standards.
filtration capacity the unit provides
power saving due to VFD working in pair with fans
EnCata developed a custom electronic storage vault for a fintech customer, integrating over 8,194 Spark™ wallets. The vault enables secure storage and blockchain-controlled transactions. We delivered enclosure design, DFM, and a functional prototype.
steel prototype with bulletproof glass
Spark™ hardware wallets incorporated
EnCata developed an 8K VR headset for sports training which featured ultra-high resolution, a wide field of view, and compact dimensions. It allowed real-time interaction between players in different places. The prototype was ready for pilot production in just 8 months.
display resolution
field of view
Reach out, and we'll show you how we approach simulations of any complexity – whether it's a wearable device or industrial equipment.
From first risk model to design-ready simulation evidence. Each stage answers a different product-readiness question.
Will the core physics of the concept work?
Which design direction is worth prototyping?
Will key components survive realistic conditions?
Does the full prototype perform as expected?
Through complex simulation projects, we’ve learned that useful FEA and CFD start before the solver runs. The model must be built around the decision the team needs to make.
We define what must not happen (overheating, cracking, resonance, leakage, pressure loss, deformation, etc.) and size the model accordingly.
A concept check takes days; a full certification model takes weeks.
We check whether standard material data is enough or whether the project needs lab testing, supplier data, or conservative assumptions. This often separates a simulation that matches reality from one that only looks precise.
We turn simulation findings into clear limits, constraints, and recommendations so mechanical or electronics engineers know what to avoid, change, or validate next.
We remove geometry that slows calculation but keep the features that control heat, stress, flow, or contact behavior.
.webp)
Related engineering services that work together with simulations to help turn physical risks into a better product, device, or industrial system.
PCB architecture, component placement, power electronics, sensor integration, and thermal constraints for devices where heat, airflow, or enclosure limits affect electronic performance.
3D CAD modeling, structural design, mechanisms, fixtures, load cases, material selection, and geometry refinement for parts that must survive real loads, heat, vibration, or pressure.
Internal layout, wall thickness, ribs, sealing, vents, cooling paths, drop resistance, IP-related constraints, and tooling-aware geometry.
Physical samples, test rigs, enclosure iterations, and validation setups that help compare simulation results with real-world product behavior.
We take the product from an unclear physical risk to validated engineering requirements that guide CAD, prototyping, testing, or production preparation.
