Aerodynamics for R&D
Automotive
We support manufacturers optimizing vehicle aerodynamics and internal airflows
Assessing aerodynamics, engine cooling and cabin ventilation
Aerodynamic drag is one of the main contributors to the energy consumption of road vehicles. As a result, aerodynamic design plays a crucial role in the performance of cars, trucks, and buses—particularly for electric vehicles, where aerodynamics directly affects driving range.
In addition to external aerodynamics, internal airflow systems are equally important. The design of air intakes influences overall vehicle drag as well as the efficiency of engine and battery cooling systems. For cabin ventilation and climate control, the layout of ventilation ducts determines system efficiency and the uniformity of temperature distribution inside the vehicle.
Our clients
Actiflow has over 20 years of experience in automotive aerodynamic analysis and design. We support car, truck and bus manufacturers in analysing and optimizing both external aerodynamics and internal airflow systems. In light of recent European regulations and CO₂ emission labelling requirements, aerodynamic optimization has become increasingly important—especially for commercial vehicles.
We collaborate with a wide range of clients: from organizations with limited in-house aerodynamic expertise to large OEMs with established aerodynamic departments. In each case, we add value by providing specialist knowledge, fresh insights, or flexible engineering capacity to support their development teams.
Our services
As specialists in automotive aerodynamics, we offer a comprehensive set of services focused on improving vehicle efficiency, performance, and compliance.
External aerodynamics
We analyse the aerodynamic performance of existing vehicles and new designs, primarily using advanced CFD (Computational Fluid Dynamics) simulations. These simulations allow us to identify key sources of aerodynamic drag and propose targeted design improvements. In many cases, relatively small geometric changes can lead to significant drag reduction. Realistic improvements can then be validated by new flow simulations.
Our work spans the entire development process—from early-stage concept design to detailed flow optimization during the engineering phase. We closely consider design intent, manufacturing constraints, and practical feasibility. Whenever possible, we validate our findings through wind tunnel testing or road tests such as coast-down measurements.
CFD services for European trailer certification and labelling
For most vehicle categories, European regulations still require road testing for certification. However, for certain vehicle types—such as trailers—the EU allows CFD simulations to replace or supplement physical testing.
Actiflow performs CFD simulations fully compliant with the EU validation procedures. These validated simulations can be used to determine trailer aerodynamic drag for official certification and labelling purposes. Our results can also be directly used as input for the VECTO tool to calculate CO₂ emissions.
Internal airflow
We analyse internal airflow through cooling ducts, pipes, and ventilation systems, which can significantly affect total vehicle drag and thermal efficiency. Our studies focus on pressure losses, flow uniformity, and heat transfer efficiency in cooling systems and HVAC units. Where needed, we propose optimized design variants and validate them through additional simulations.
Passenger comfort and health are also key considerations. For example, effective cabin airflow in buses is essential to reduce the spread of airborne particles such as viruses. Optimization of ventilation systems and minimizing their energy consumption is even more important for electric vehicles, for which the energy balance is most critical.
Using CFD simulations, we assess airflow patterns, system efficiency, and energy consumption. Based on the results, we provide clear conclusions, design recommendations, and validated optimization concepts.
How we work
CFD simulations are the primary tool in our automotive analysis and design projects. In addition, we have access to wind tunnel facilities and collaborate with partners for road testing when required.
Our added value lies in our deep CFD expertise. With more than 20 years of experience in automotive aerodynamics, Actiflow uses CFD as the main driver for analysing and optimizing vehicle aerodynamics. Today, CFD is the most important tool in the aerodynamic design process, while wind tunnel and road testing are typically used for final validation.
Over the years, we have seen quite some advancements in CFD used for automotive design. While steady-state simulations were once the standard, most clients now request transient simulations to gain deeper insights and improve result reliability. multiple CFD software to ensure the best possible solution for each client.
Used tools:
Relevant Projects
Collaboration HWA
Collaboration HWA
Rotterdam, The Netherlands
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