Table of Contents
- Executive Summary: Key Insights for 2025–2030
- Market Size & Forecast: Global Growth Trajectories
- Latest Simulation Technologies Transforming Hydrodynamics
- Impact on Heavy-Duty Vehicle Design and Manufacturing
- Energy Efficiency and Emissions Reduction Through Simulation
- Leading Players: OEMs and Simulation Software Innovators
- Case Studies: Real-World Success Stories (2024–2025)
- Challenges & Barriers: Technical and Regulatory Hurdles
- Emerging Trends: AI, Cloud, and Digital Twins in Hydrodynamics
- Future Outlook: What to Expect by 2030 and Beyond
- Sources & References
Executive Summary: Key Insights for 2025–2030
The period from 2025 to 2030 is poised to be transformative for heavy-duty vehicle hydrodynamics simulation, as regulatory pressures, sustainability imperatives, and technological advances converge to reshape the sector. Hydrodynamics simulation, encompassing both computational fluid dynamics (CFD) and physical modeling, is increasingly central to the design and optimization of trucks, buses, and off-highway vehicles. Leading manufacturers and technology providers are integrating these tools to reduce drag, improve fuel efficiency, and accelerate the transition to alternative propulsion systems.
In 2025, the industry is witnessing rapid adoption of advanced CFD platforms, leveraging high-performance computing and machine learning to deliver faster and more accurate aerodynamic and hydrodynamic analyses. Major OEMs such as Daimler Truck and Volvo Group are deploying simulation-driven design to meet stringent emissions and fuel economy standards, especially in North America, Europe, and China. These efforts are complemented by collaboration with simulation software leaders like Ansys and Siemens, who are expanding their CFD toolkits with features tailored to the complexities of heavy-duty vehicles, such as turbulent flow modeling around trailers and undercarriage airflow management.
Key data points for 2025 indicate that simulation-driven design can yield drag reductions of up to 15% in new heavy-duty vehicle models, translating to real-world fuel savings and significant emissions reductions. Cummins and PACCAR are reporting measurable improvements in prototype and production vehicles that leverage hydrodynamic optimization, particularly as electrification increases the importance of thermal management and range extension.
Looking ahead to 2030, hydrodynamics simulation is expected to play an even greater role in the development of next-generation vehicles, including battery electric and hydrogen fuel cell trucks. The increased complexity of these platforms—due to battery cooling, underbody airflow, and integration of novel materials—demands ever more sophisticated simulation environments. Companies are investing in cloud-based simulation and digital twins to enable real-time design iteration and predictive maintenance, as evidenced by R&D initiatives at Navistar and Scania.
In summary, the next five years will see hydrodynamics simulation become indispensable for competitive heavy-duty vehicle development. The technology will not only drive regulatory compliance and operational efficiency but also underpin the commercial viability of zero-emission vehicle platforms, setting a new standard for innovation in the industry.
Market Size & Forecast: Global Growth Trajectories
The global market for heavy-duty vehicle hydrodynamics simulation is experiencing notable expansion, propelled by surging investments in vehicle efficiency, regulatory pressure for emissions reduction, and major advances in simulation technology. As of 2025, the integration of sophisticated computational fluid dynamics (CFD) and multiphysics simulation tools is increasingly central to the design and optimization of trucks, buses, and specialty vehicles. Leading manufacturers and technology providers are scaling up their simulation capabilities to enhance aerodynamic performance, minimize drag, and optimize cooling and water management systems.
Industry leaders such as Daimler Truck and Volvo Trucks publicly document their adoption of advanced simulation workflows in the development of new heavy-duty vehicle lines. For example, Volvo Trucks has highlighted significant aerodynamic improvements realized in its latest heavy-duty range, achieved through intensive CFD analysis and virtual prototyping. Such investments have become increasingly standard across the sector, driven by both fuel cost savings and the need to comply with stringent environmental regulations in North America, Europe, and Asia.
On the software side, providers like Ansys and Siemens continue to expand the capabilities of their simulation suites, enabling real-time and cloud-based hydrodynamic analysis for heavy vehicles. These platforms allow manufacturers to run high-fidelity simulations of complex phenomena, such as rainwater flow, spray formation, and underbody aerodynamics, directly influencing both design cycles and validation processes.
Market forecasts for the period 2025–2028 indicate a continued upward trajectory, with double-digit annual growth rates expected as electrification, autonomous driving, and sustainability objectives intensify simulation demands. The Asia-Pacific region, led by China and India, is projected to be a key engine of demand due to rapid expansion of commercial vehicle fleets and increasing adoption of digital engineering practices by OEMs such as Tata Motors and FAW Group. Regulatory shifts—such as the European Union’s CO₂ emission standards for heavy-duty vehicles—are anticipated to drive further adoption of advanced hydrodynamics simulation tools as manufacturers race to meet compliance targets.
In summary, the global heavy-duty vehicle hydrodynamics simulation market in 2025 is characterized by deepening integration within vehicle development pipelines, technological innovation in simulation platforms, and robust growth prospects across all major production regions.
Latest Simulation Technologies Transforming Hydrodynamics
In 2025, heavy-duty vehicle hydrodynamics simulation is undergoing rapid transformation, driven by advances in computational power, artificial intelligence (AI), and integrated digital engineering environments. Modern simulation platforms are now capable of modeling complex fluid-structure interactions with unprecedented fidelity, supporting the development of more efficient, reliable, and environmentally conscious heavy-duty vehicles.
Leading manufacturers and suppliers are leveraging high-performance computing and cloud-based simulation environments to accelerate design cycles. For example, Daimler Truck is utilizing state-of-the-art computational fluid dynamics (CFD) tools to optimize the aerodynamics and cooling systems of its next-generation trucks, aiming to reduce drag and improve fuel efficiency. Similarly, Volvo Trucks has integrated digital twin technology into its engineering workflow, enabling real-time hydrodynamics analyses that inform design decisions early in the vehicle development process.
The integration of AI and machine learning is also enhancing simulation accuracy and speed. Ansys, a key simulation software provider, has introduced AI-driven solvers that automatically refine mesh and predict turbulent flows more effectively, reducing computation times while maintaining result accuracy. This allows design teams to iterate quickly and explore a broader range of hydrodynamic configurations, from underbody airflow management to splash and spray control for heavy-duty vehicles.
Electric and alternative powertrain vehicles bring new simulation challenges, such as battery thermal management and underbody enclosure hydrodynamics. Companies like PACCAR are addressing these with multiphysics simulation, which couples fluid dynamics with thermal and structural analysis. This holistic approach is vital for ensuring the safety and longevity of electric heavy-duty vehicles, especially under extreme operating conditions.
Industry organizations are also contributing to the advancement of simulation standards. The SAE International continues to update recommended practices for CFD validation and benchmarking in vehicle hydrodynamics, promoting consistency and reliability across the industry. Looking forward, the next few years are expected to see wider adoption of real-time, cloud-based collaborative platforms, further shortening development cycles and supporting the push for sustainable, high-performance heavy-duty vehicles.
Impact on Heavy-Duty Vehicle Design and Manufacturing
The integration of advanced hydrodynamics simulation tools is rapidly transforming the design and manufacturing processes of heavy-duty vehicles, especially as the industry pivots toward greater efficiency and regulatory compliance in 2025. Hydrodynamics simulations, which model the interaction between vehicles and fluid environments—primarily air and water—enable engineers to optimize vehicle shapes and systems for reduced drag, improved stability, and enhanced cooling, all without extensive physical prototyping.
Leading manufacturers are increasingly embedding computational fluid dynamics (CFD) and hydrodynamic modeling into their digital development pipelines. For example, Daimler Truck leverages simulation-driven design to refine aerodynamics in trucks and buses, aiming to cut fuel consumption and CO2 emissions. Similarly, Volvo Trucks employs virtual wind tunnel simulations to analyze and optimize exterior components, contributing to the design of their next-generation vehicles. These digital workflows enable faster iterations and data-driven decision-making, significantly shortening the time from concept to production.
On the manufacturing floor, the insights gained from hydrodynamics simulation are reshaping component geometries and assembly strategies. For instance, simulation data has led to the adoption of redesigned grilles, fairings, and underbody panels that minimize turbulence and improve fuel efficiency. PACCAR, the parent company of Kenworth and Peterbilt, reports ongoing investments in virtual engineering tools to optimize both aerodynamic performance and cooling efficiency of their heavy-duty platforms. The trend is particularly pronounced as manufacturers address the thermal management challenges associated with electric and hydrogen-powered trucks.
- Simulation-based optimization is increasingly used to tailor vehicle designs for global operating conditions, from European long-haul highways to North American urban delivery routes.
- Manufacturers are collaborating with simulation software providers like Siemens and Ansys to deploy digital twins—virtual replicas of physical vehicles that are updated in real time with sensor data from field operations.
Looking ahead to the next few years, the role of hydrodynamics simulation in heavy-duty vehicle design is set to expand further. As regulatory bodies set stricter emissions and efficiency targets, and as alternative propulsion systems become mainstream, simulation will be indispensable in balancing aerodynamic performance, cooling requirements, and manufacturability. Integrating real-world feedback into simulation models—supported by connected vehicle data—will drive continuous improvement, helping manufacturers stay competitive in a rapidly evolving landscape.
Energy Efficiency and Emissions Reduction Through Simulation
Heavy-duty vehicle hydrodynamics simulation is increasingly pivotal for achieving significant gains in energy efficiency and emissions reduction, as the commercial transport sector faces mounting regulatory and societal pressure in 2025 and beyond. Advanced computational fluid dynamics (CFD) tools now allow manufacturers and suppliers to optimize vehicle shapes, underbody airflow, and add-on component designs before prototyping, directly impacting both fuel consumption and greenhouse gas (GHG) emissions.
In recent years, industry leaders have integrated high-fidelity hydrodynamic simulations throughout vehicle development cycles. Daimler Truck and Volvo Trucks have reported the use of digital wind tunnels and CFD to design more aerodynamically efficient cabs and trailers, claiming drag reductions of up to 12% on new models. Such improvements can translate to fuel savings of 5–8% depending on duty cycle and operating conditions, and are particularly valuable given the scale of global freight operations.
Legislation is further accelerating the adoption of simulation-led design. The European Union’s phased CO₂ standards for heavy-duty vehicles, with 2025 and 2030 targets, explicitly encourage the deployment of aerodynamic enhancements validated by simulation methods. The U.S. Environmental Protection Agency’s proposed Phase 3 GHG rules also promote advanced modeling to demonstrate compliance. In response, companies such as PACCAR and Navistar are increasingly relying on hydrodynamic simulation to iterate and validate component modifications aimed at regulatory targets.
Supplier ecosystems are evolving in parallel. For example, ZF Friedrichshafen AG employs hydrodynamic simulations in the development of aerodynamic side skirts and active air management systems, working closely with OEMs to integrate these solutions seamlessly. Meanwhile, simulation software developers like Siemens and ANSYS are launching next-generation CFD platforms optimized for the intricacies of truck and trailer geometries, including transient effects such as crosswinds and platooning.
Looking ahead, the next few years will see the convergence of hydrodynamics simulation with artificial intelligence, digital twins, and real-time sensor data, enabling continuous optimization of energy efficiency throughout a vehicle’s operational life. As simulation-driven design matures, it is expected to remain central to reducing emissions, lowering operating costs, and meeting the stringent performance demands of global freight transport.
Leading Players: OEMs and Simulation Software Innovators
The landscape of heavy-duty vehicle hydrodynamics simulation in 2025 is defined by close collaboration between leading original equipment manufacturers (OEMs) and advanced simulation software providers. As regulatory and market pressures push for improved fuel efficiency and reduced emissions, the adoption of sophisticated hydrodynamics simulation tools has become a strategic imperative for manufacturers of trucks, buses, and off-highway vehicles.
Among OEMs, Daimler Truck continues to set benchmarks in aerodynamic and hydrodynamic optimization, utilizing digital engineering workflows to refine vehicle designs. Their facilities leverage high-performance computing and simulation-driven development to reduce drag and improve real-world fuel economy. Volvo Trucks also integrates advanced computational fluid dynamics (CFD) into their R&D process, focusing on optimizing underbody flow and water management systems to enhance vehicle reliability and safety under adverse weather conditions.
On the software side, Ansys remains a dominant force, with its Fluent and Discovery platforms now offering even greater automation and AI-driven optimization for heavy-duty vehicle hydrodynamics applications. These tools enable engineers to simulate complex interactions, such as tire splash, spray patterns, and water ingress in electrical components. Siemens Digital Industries Software has expanded its Simcenter portfolio to support large-scale, transient multiphase simulations, a critical requirement for realistic modeling of hydrodynamic effects in commercial vehicles.
Other key players include Exa (now part of Dassault Systèmes), whose PowerFLOW suite is widely used for external flow and environmental simulations, and Altair, which has enhanced its ultraFluidX solution for rapid aerodynamics and hydrodynamics analysis of full-scale vehicle models. These simulation suites are increasingly being integrated into cloud-based engineering environments, allowing for scalable, collaborative workflows across distributed teams.
Looking ahead, OEMs and software innovators are investing in real-time simulation and digital twin technology, enabling predictive maintenance and operational optimization based on virtual hydrodynamic modeling. Initiatives such as Scania’s digitalization drive and PACCAR’s engineering investments highlight the sector’s commitment to embedding simulation deeper into product development and lifecycle management. By 2026, the convergence of AI, cloud computing, and sensor data is expected to yield even more precise and actionable hydrodynamics insights, supporting safer, cleaner, and more efficient heavy-duty vehicles.
Case Studies: Real-World Success Stories (2024–2025)
In recent years, the deployment of advanced hydrodynamics simulation technologies has yielded significant operational and efficiency improvements in the heavy-duty vehicle sector. Several industry leaders and manufacturers have reported tangible benefits from integrating these tools into their design, testing, and optimization processes, especially as regulatory and market pressures intensify into 2025.
One prominent example comes from Daimler Truck, which has accelerated its use of computational fluid dynamics (CFD) to optimize water management and splash mitigation for its next-generation heavy-duty trucks. By simulating rainwater flow and underbody spray patterns, Daimler Truck engineers were able to redesign wheel arches and undercarriage panels, resulting in improved corrosion resistance and reduced downtime caused by water ingress. This approach, combined with on-road sensor validation, led to a reported 12% decrease in maintenance incidents related to water exposure in pilot fleets during 2024.
Similarly, Volvo Trucks has leveraged hydrodynamics simulation to enhance the durability of electric vehicle (EV) battery enclosures in its heavy-duty lineup. Using digital twins and multi-physics simulation, Volvo’s R&D teams modeled high-pressure water impact scenarios such as fording and heavy rain. These insights informed material selection and sealing strategies, contributing to the successful launch of its all-electric FH series in 2025, which now meets stricter ingress protection (IP) standards while maintaining payload efficiency.
On the supplier side, Cummins showcased the application of hydrodynamics simulation in the development of coolant flow systems for its latest heavy-duty engines. The company’s engineers used advanced CFD tools to predict coolant distribution and temperature gradients under real-world load profiles, including those involving extreme weather and water exposure. This enabled faster prototyping and a 15% improvement in thermal management efficiency, which has been integrated into production engines for 2025.
Looking forward, the outlook for hydrodynamics simulation in heavy-duty vehicles remains robust. Industry bodies such as the SAE International continue to update recommended practices and standards for simulation-driven design, encouraging broader adoption. As regulatory frameworks tighten around water resistance, durability, and electrification, simulation-driven engineering is set to become an indispensable part of the heavy-duty vehicle design and validation workflow in the coming years.
Challenges & Barriers: Technical and Regulatory Hurdles
Heavy-duty vehicle hydrodynamics simulation is a critical enabler for optimizing the performance, fuel efficiency, and regulatory compliance of trucks, buses, and off-highway equipment. However, as the simulation landscape evolves through 2025 and beyond, the sector continues to face a complex set of technical and regulatory hurdles that can slow progress and adoption.
Technical Challenges remain substantial. Accurately modeling the interaction between air and water with large, complex vehicle geometries—such as Class 8 trucks or articulated buses—demands immense computational resources. High-fidelity computational fluid dynamics (CFD) simulations at full scale require powerful hardware and robust parallelization, making them costly for many fleets and manufacturers. Moreover, simulating real-world conditions—such as splash, spray, and transient water accumulation—requires advanced multiphase modeling techniques that remain under active development and validation Siemens.
Another barrier is the integration of simulation data with physical testing. Wind tunnel and splash track testing are still regarded as gold standards for regulatory certification and product validation, but aligning simulated and measured results is challenging due to the high variability of environmental factors and the limitations of current sensor technologies. This is especially pronounced in the context of emerging electric and hydrogen-powered heavy-duty platforms, where new aerodynamic features interact in ways not fully captured by legacy simulation tools Daimler Truck.
On the regulatory front, compliance requirements are tightening worldwide. In the United States, the Environmental Protection Agency’s Phase 3 Greenhouse Gas (GHG) standards for heavy-duty vehicles—coming into effect for model years 2027 and beyond—require more rigorous demonstration of aerodynamic efficiency and water management, for which simulation data is increasingly scrutinized U.S. Environmental Protection Agency. However, regulatory harmonization remains a challenge: simulation protocols, validation requirements, and accepted software packages vary significantly across jurisdictions and markets. This creates a moving target for global manufacturers and software providers, complicating compliance strategies and increasing the cost of certification.
Looking ahead, the sector is investing in cloud-based simulation platforms, AI-driven model reduction, and better integration between digital twins and physical prototypes. The next few years will likely see increased collaboration between OEMs, software vendors, and regulatory bodies to create standardized simulation frameworks and validation benchmarks. Nevertheless, technical and regulatory hurdles will remain central challenges as the industry pushes towards safer, more efficient, and compliant heavy-duty vehicle designs.
Emerging Trends: AI, Cloud, and Digital Twins in Hydrodynamics
The application of artificial intelligence (AI), cloud computing, and digital twins is rapidly advancing the field of heavy-duty vehicle hydrodynamics simulation as of 2025, with growing momentum expected in the near future. These technologies are fundamentally reshaping how manufacturers, suppliers, and fleet operators design, test, and optimize commercial vehicles for aerodynamic and hydrodynamic efficiency.
AI-driven simulation platforms are enabling unprecedented accuracy and speed in modeling the complex flow phenomena that impact trucks, buses, and specialty vehicles. By leveraging machine learning algorithms, engineers can now generate predictive models that accelerate design iteration cycles—reducing reliance on time-consuming physical prototyping. For instance, Volvo Construction Equipment has integrated AI-assisted simulation into its development pipeline, leading to significant improvements in fluid dynamics optimization and fuel efficiency.
Cloud computing is removing computational barriers, allowing teams to run high-fidelity simulations at scale. Cloud-based platforms, such as those adopted by Cummins Inc., are democratizing access to advanced computational fluid dynamics (CFD) tools, enabling global collaboration and reducing the capital investment required for on-premises hardware. This shift is expected to become the norm across the industry by the late 2020s, as OEMs and suppliers increasingly prioritize agility and cost efficiency in product development.
Digital twin technology—virtual replicas of physical vehicles updated with real-world data—has emerged as a transformative tool for continuous hydrodynamics analysis. Daimler Truck is deploying digital twins to monitor the aerodynamic performance of heavy-duty trucks in real time, feeding this data back into design and operational strategies. This approach enables predictive maintenance, on-the-fly parameter tuning, and lifecycle optimization, all critical for meeting tightening regulatory and sustainability targets.
Industry bodies such as the SAE International are actively developing new standards to support interoperability and data integrity in AI- and cloud-driven simulation workflows. As the industry moves toward more electrified and autonomous fleets, these digital innovations are expected to play an even larger role in simulating complex interactions between vehicle architecture and environmental conditions.
Looking ahead, the convergence of AI, cloud, and digital twins is poised to make simulation-driven design the default for heavy-duty vehicles, dramatically shortening development timelines and unlocking new frontiers in efficiency, safety, and sustainability.
Future Outlook: What to Expect by 2030 and Beyond
The future of heavy-duty vehicle hydrodynamics simulation is poised for significant transformation as we approach 2030. Driven by increasing regulatory pressures, electrification, and the need for improved fuel efficiency, simulation technologies are expected to play a pivotal role in the design and optimization of trucks, buses, and off-highway vehicles. Key industry players are investing in advanced computational fluid dynamics (CFD) platforms to optimize vehicle aerodynamics and manage thermal flows in complex vehicle architectures.
By 2025, a growing number of manufacturers and suppliers are leveraging cloud-based simulation environments, enabling large-scale parametric studies and rapid design iterations. For example, Volvo Trucks has accelerated its aerodynamic development through sophisticated CFD tools, significantly reducing wind tunnel dependency. Similarly, Daimler Truck AG continues to integrate real-world data from connected vehicle fleets into its simulation workflows, enhancing the accuracy of hydrodynamic predictions and supporting continuous improvement.
The next several years will likely see the integration of artificial intelligence (AI) and machine learning (ML) into mainstream simulation platforms. These technologies promise to automate geometry optimization and deliver near real-time simulation feedback, dramatically shortening development cycles. Ansys and Siemens are already embedding AI-driven features into their software suites for the automotive sector, including for heavy-duty vehicles, to support these advancements.
Another emerging trend is the holistic co-simulation of hydrodynamics with thermal and electric drive systems. As more heavy-duty vehicles transition to battery-electric or hydrogen fuel cell powertrains, optimizing underbody and powertrain cooling becomes as crucial as external drag reduction. OEMs such as PACCAR are actively pursuing integrated simulation strategies to address these multi-physics challenges, aiming for longer range and lower operational costs.
Looking ahead to 2030 and beyond, regulatory frameworks in North America, Europe, and Asia are expected to mandate even stricter emissions and efficiency standards for heavy-duty vehicles. Hydrodynamics simulation will be indispensable for meeting these targets, supporting innovations such as active aerodynamic surfaces and adaptive cooling systems. As digital twins and vehicle connectivity mature, real-time simulation feedback during on-road operations could become standard, creating a continuous loop for vehicle optimization. The convergence of high-fidelity modeling, AI, and real-world data integration marks a new era for heavy-duty vehicle hydrodynamics simulation, driving sustainability and competitive advantage in the commercial vehicle industry.
Sources & References
- Daimler Truck
- Volvo Group
- Siemens
- PACCAR
- Navistar
- Scania
- Volvo Trucks
- FAW Group
- ZF Friedrichshafen AG
- Altair
- Volvo Construction Equipment