Design of technical parts for HVAC systems

Technical parts for HVAC systems today must withstand a series of challenges: not only their performance must be long-lasting and efficient, but they must also provide optimal acoustic insulation, guarantee energy savings and be aesthetically pleasant. Thus, the HVAC design process must take into account all these goals.

We analyze current needs for HVAC parts and how the design process can address them.

Basic principles of technical parts design 

HVAC systems (Heating, Ventilation, and Air Conditioning systems) are in charge of an essential part of any building: regulating its temperature and air quality. In order to do so, there are two crucial principles to be taken into account when designing them:

Components in HVAC systems

  • Heating equipment such as hot water or steam boilers, heat exchangers, control air compressors, pressure-reducing systems and pumps.
  • Air delivery equipment, including axial fans, centrifugal fans, and plug or plenum fans, as well as outdoor air intake systems
  • Refrigeration equipment such as cooling coils, water chillers, or refrigerants, as well as a cooling tower and control air compressors, among others.
  • Ducts and pipes to conduct air. These deliver hot and cooled water, steam, gas, and refrigerant, and should be correctly insulated in order to avoid any potential heat loss.
  • Dehumidification and humidification equipment

HVAC system design requirements  

Each HVAC system’s requirements will depend on the given climate, the building’s characteristics and the owners’ needs, as well as the allocated budget.

The following include the main space requirements for the installation of HVAC systems:

  • HVAC facilities: where both the heating and refrigeration equipment can be installed. This installation should consider the size and weight of equipment, as well as regulations for ventilation and combustion processes.
  • Equipment rooms: these are typically located in a central area of the building in order to avoid complex duct and pipe systems. This room should allow for the movement of heavy and big equipment in order to facilitate maintenance operations, among others.
  • Ventilation  rooms are located in a specific room, which can include other equipment. This room should have easy access to outdoor air.
  • A vertical shaft is also necessary for water and steam pipe distribution, as well as for air distribution. 

At the same time, there are some requirements that address current HVAC possibilities regarding efficiency and comfort. This means ductwork should deliver air in a quiet, direct and cost-efficient way. 

Today, energy savings are regarded as a must in HVAC design, so that ductwork is devised from the beginning to be insulated and able to prevent heat loss. 

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HVAC design for technical parts: the process

Graphic design software

Specific graphic design software is used to generate the HVAC models so that they can be analyzed and verified prior to manufacturing the final product.

At this initial stage, it’s possible to determine the system’s appearance and its material requirements, so that processes and costs can be optimized. 

3D Prototype of technical parts

After the graphic design process, it’s time to create a machine-generated 3d prototype, which can be analyzed for nonconformities and taken back to the initial stage in order to implement the necessary changes. 

Sample approval

Prototypes are built to be verified by the client so that functional parameters and aesthetics can be examined. At this point, the client can accept the prototype or make a series of recommendations and comments so that they are amended.

The sample approval leads to the next step before manufacturing, when an EPP product using an aluminum mould is fabricated so that the first real samples are verified.


The manufacturing process can then take place, including mass production plans. 

Knauf Appliances: from the drawing board to the final product 

At Knauf Appliances we help companies design custom-made solutions for their technical parts in HVAC systems.


Thanks to our long experience as moldable-plastic technical parts manufacturers, we guarantee a highly efficient process that generates cost-effective and optimised HVAC parts.


Benefits of using EPP for HVAC parts

Expanded Polypropylene or EPP stands out as the ideal expanded foam for HVAC design. This material’s main benefits include:

  • Provides extraordinary thermal insulation. It helps prevent heat loss in heating units, because of its low thermal conductivity
  • Generates acoustic insulation
  • Impressive mechanical strength and highly resistant to breakage and deformation
  • Extremely lightweight
  • Flexibility, which massively simplifies assembly and installation processes and, in turn, reduces production costs. At the same time, it allows for the creation of complex shapes and tailor-made design. Modular insulation models are also possible
  • The capacity to withstand advanced engineering designs using 3D technology
  • Useful both for frameworks and internal components

At Knauf Appliances we focus on solving our clients’ needs, analysing their current necessities and providing optimised and cost-efficient solutions for custom-made EPP HVAC systems.

Want to learn more about how to have access to technical parts for HVAC systems that are both long-lasting and energy-efficient? Get in touch with us and let’s talk about how we can help you.

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