From cars to plants – why 1D simulation is experiencing a renaissance right now
Introduction
“1D simulation? Is that still a thing?”
I've been hearing this question a lot lately. In fact, traditional 1D calculation engineers in the automotive industry—from trucks to passenger cars—are facing difficult times. The market is saturated, the models are mature, and many systems are now simulated directly in 3D.
But as is so often the case, when one door closes, another opens.
And this door is currently wide open—in industry, in energy technology, and in the digitalization of development processes.
Together with TheSys, we take a look at Merkle CAE Solutions to see where 1D simulations outside the automotive world really make sense today – and where the combination of 1D, 3D, and thermal engineering is not only useful but crucial.
Electrical energy storage – when it gets too hot, it gets expensive
Energy storage is one of those topics that immediately brings lithium-ion cells to mind—and what happens when they get too hot: nothing good.
Thermal management is essential here.
The batteries should smile at 25 °C, but neither freeze nor boil.
Too hot? Aging, gas development, fire.
Too cold? Loss of performance, loss of charging capacity.
In our 1D simulations, we can map the entire cooling system:
from the chiller to the low-temperature circuit to the cell contacts.
This allows us to see where the heat is generated, how it flows, and when it becomes critical—before the first prototype even exists.
And best of all, the 1D results provide the input variables for the 3D FEM calculation. This allows us to evaluate service life, aging, and safety together—virtually, reproducibly, and without setting off the smoke alarm in the lab.
Cooling systems for industrial applications – from data centers to electrolysers
While almost everything in the automotive industry has already been optimized, the situation is quite different in other industries:
Whether data centers, fuel cell systems, aircraft, ships, or electrolysers—cooling is used everywhere, often at great expense and frequently inefficiently.
The rule of thumb is: every liter of water that does not have to be recirculated saves energy.
And every kilowatt hour that is recovered from waste heat is a gain for the climate and the bottom line.
With 1D simulations, we can model complex cooling circuits, compare variants, and weigh up costs against performance—before a single pipe is bent.
The modular design is particularly exciting: series components that can be flexibly adapted to different systems via parameters—from combined heat and power plants to marine diesel engines.
This transforms a simple cooler into a genuine energy management solution.
Digital development process – when tools finally talk to each other
A topic that annoys many engineers:
You have the best simulation in the world—but the office next door uses different software, and the interface between them is... let's call it “improvable.”
This is where we come in, together with TheSys:
By linking 0D, 1D, 3D, and FE tools, processes can be digitally integrated.
What used to happen in three departments and five Excel spreadsheets now runs in a consistent, standardized model.
The result:
- Fewer interface problems
- Faster coordination
- Clear data chains from simulation to testing
In short: Engineers can finally get back to calculating instead of maintaining data.
And when everything is neatly linked, a real digital twin is created – what used to be affectionately known as “testing with less stress.”
Conclusion – 1D lives on. Just differently.
1D simulation is not a thing of the past; it is a tool undergoing change.
What began in the automotive sector is now continuing in industry, energy, and process engineering.
With TheSys as a strong partner, we are expanding our portfolio in a targeted manner into new industries—with a focus on thermal engineering, tool coupling, and synergies between 1D and 3D.
Because one thing remains certain:
As long as something flows, streams, cools, or heats up, there is something to simulate.
And that is exactly what we are here for.
Yours Stefan Merkle
