Propel Industries partnered with Messen Labs and Altair to optimize cooling system design for electric heavy-duty trucks operating under extreme conditions. Thermal management was critical due to high power demands and harsh environments. Using Altair CFD and system-level simulation, engineers modeled the complete cooling circuit, including radiators, pumps, motors, inverters, and control units. Transient simulations captured thermal and flow behavior across multiple operating modes and drive cycles. Results were validated against physical test data with 85–90% accuracy. The approach enabled proper sizing of components, reduced prototype iterations, and delivered a first-time-right design, significantly shortening the product development cycle while improving system reliability and perform

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