Analysis of Automotive Intake Components

OVERVIEW We are an automotive performance parts company developing two products that are through the CAD design phase and now need CFD analysis before we finalize the designs. We are looking for a CFD engineer with automotive intake/airflow experience to analyze both parts, and just as importantly, to help us define the right test parameters. Our in-house designer handled all the CAD work but CFD is outside his wheelhouse, so we need someone who can lead the simulation side and collaborate directly with him. THE TWO PARTS Part 1: Air-to-water intake manifold for the BMW M30 engine (E34 chassis). A custom intake manifold for the BMW M30 inline-6, designed with an integrated air-to-water intercooler core, intended for boosted applications. Part 2: 4150-flange intake elbow. An intake elbow with a 4150 flange pattern, accepting an LS-pattern throttle body, intended mostly for boosted applications. Additional throttle body patterns will be offered down the road, so recommendations that hold up across throttle body variants (or guidance on what would need re-checking per variant) are a plus. Both models were designed in Fusion 360 and are complete. We can export STEP, IGES, or another neutral format of your preference, or share native Fusion 360 files if you work in it. WHAT WE NEED FROM YOU Parameter definition (consultation). We know our engine specs and power goals, but we are not sure how to translate those into simulation boundary conditions (boost pressure, mass flow rates, operating points, etc.). We want you to walk us through what should be tested and why, and agree on a test matrix with us before running anything. CFD analysis of both parts at the operating points we agree on. For the manifold specifically, we want to understand runner-to-runner flow distribution across the six runners. For both parts, we want pressure drop / flow restriction numbers and overall flow capacity. Design feedback. Concrete, actionable geometry recommendations our designer can implement. We are open to a revision loop where he updates the model based on your findings and you re-run to confirm the improvement (tell us in your proposal how you would price a revision pass). Presentation-quality results. In addition to the engineering report, we plan to use results to support product claims, so we need clean, high-resolution flow visualizations (velocity and pressure contours, streamlines) and clearly stated numbers we can reference publicly with confidence. DELIVERABLES Agreed test matrix / boundary condition document (so we understand what was tested and why) CFD report for each part: pressure drop, flow capacity, and (for the manifold) runner-to-runner distribution High-resolution images/renders of flow visualizations suitable for marketing use Written design improvement recommendations A call or two with our designer to review findings and answer questions WHAT WE PROVIDE Finished CAD models (Fusion 360 native, or STEP/IGES export - your preference) Engine specifications and target power/boost goals for the intended applications A responsive point of contact (our designer) for any geometry questions or cleanup HOW TO APPLY Please include in your proposal: Which CFD software you use and your general approach for internal-flow analysis of intake components Examples of prior automotive intake/manifold/airflow CFD work (images or reports, redacted is fine) How you would handle the air-to-water intercooler core inside the manifold in the simulation What information you need from us to set boundary conditions, and how you would run the parameter-definition conversation Your proposed pricing structure for both parts (fixed, milestone-based, or hourly - your call, just explain it), and how you would price an optional revision/re-run pass Estimated timeline from receiving the CAD files to delivering both reports We are open to different pricing approaches and will evaluate proposals on relevant experience, clarity of approach, and communication. Freelancers who clearly explain their methodology in plain language will stand out, since part of this job is helping us understand the results, not just producing them.