Maximize efficiency, uptime, and capacity in AI and high-density data centers with high-fidelity CFD, digital twins, and system-level simulation
Reduce energy costs, eliminate thermal risk, and boost performance across your data center with advanced CFD simulations. Get clear, actionable insights — so you can make smarter infrastructure decisions with confidence.
The Challenge: Thermal Management in Modern Data Centers
AI training and inference clusters, high-density GPU racks, and rising power densities (often 50–120+ kW per rack) are pushing traditional cooling approaches to their limits. Cooling can consume 25–40% of facility power. Hot spots, recirculation, and uneven temperatures lead to throttling, reduced equipment life, and downtime risk.
Rules of thumb and sequential design no longer scale. Simulation-driven design and operational digital twins give operators the insight needed to support higher densities more reliably and cost-effectively.
How TotalSim US Helps
We use the Siemens Simcenter Portfolio (including STAR-CCM+, Simcenter 3D, Simcenter FloTherm, Simcenter FloMaster, Simcenter HEEDS, and Simcenter Amesim) to deliver:
- Facility-level CFD – Full airflow, pressure, and temperature mapping
- Hot-spot diagnosis and remediation – Root-cause analysis and targeted fixes
- Design optimization – Automated exploration of layouts, containment, and cooling capacity with HEEDS
- Failure-mode and resilience studies – Performance under partial HVAC failure
- Liquid and hybrid cooling evaluation – Safe, efficient integration of liquid cooling
- Operational digital twins – Calibrated models that support ongoing decision-making
Optimize Data Center Design and Performance
Data centers present unique challenges in thermal
management and airflow optimization. Engineers and
designers must ensure efficient cooling while
minimizing energy use and avoiding downtime. Our
CFD simulations help customers understand the
following:
- Airflow circulation throughout the enclosure
- Identification of hot spots and under-cooled
regions - Optimal placement of HVAC and cooling units for
effective coverage - Predict temperature behavior under various
equipment failure scenarios
Optimizing Data Center Cooling with STAR-CCM+ and TotalSim Expertise Case Study
Data centers present unique challenges in thermal management and airflow optimization. Engineers and designers must ensure efficient cooling while minimizing energy use and avoiding downtime. Our CFD simulations help customers understand the following:
- Initial analysis revealed inadequate airflow coverage, resulting in hot spots where temperatures exceeded critical thresholds by 10–15%.
- Based on our recommendations, the team redistributed the server hardware to balance heat loads more effectively.
- We proposed a redesign of the HVAC system, including the addition of a bi-directional unit to cool a thermally isolated corner of the room.
- Post-redesign simulations showed that all monitored zones were maintained at temperatures 5–10% below critical thresholds, even under partial system failure.