Simulation-driven design: A game-changer for design engineers
By David Danfer
Simulation-driven design is reshaping how we approach product development. No longer constrained by traditional trial-and-error prototyping, design engineers can now leverage advanced simulation tools to enhance design accuracy, reduce costs, and accelerate time to market. This methodology integrates simulation early in the design phase, making it a critical asset in achieving robust, optimised, and innovative products.
What is simulation-driven design?
Simulation-driven design (SDD) involves using computer-aided engineering (CAE) tools to validate and optimise designs through virtual testing before a physical prototype is even built. By running simulations such as finite element analysis (FEA), computational fluid dynamics (CFD), and other multiphysics simulations, engineers can predict how a design will behave under real-world conditions.
This process helps to catch design flaws early, optimise materials usage, and ensure compliance with safety and performance standards, all while maintaining an agile workflow.
Key benefits from a design engineer's perspective
- Improved design efficiency
Simulation tools allow for iterative testing and refinement without needing physical prototypes at every stage. Engineers can run multiple simulations, tweak parameters, and optimise designs in a virtual environment. This rapid feedback loop significantly shortens design cycles.
- Cost savings
Traditional product development relies heavily on prototyping, which is expensive and time-consuming. With SDD, many prototypes can be virtual, reducing material costs and labour while also cutting the number of physical iterations.
- Risk reduction
By simulating real-world conditions, engineers can anticipate product failures, identify stress points, and understand material limitations before manufacturing begins. This reduces the likelihood of costly product recalls and ensures the product meets quality and safety standards.
- Design optimisation
One of the major advantages of SDD is the ability to fine-tune designs for optimal performance. Engineers can explore different materials, geometries, and configurations to find the best balance between strength, durability, and cost. Parametric optimisation algorithms can also help automatically iterate and improve the design based on performance metrics.
- Multiphysics capabilities
Complex products often require more than just structural analysis. With simulation-driven design, engineers can combine different physical phenomena (thermal, fluid, mechanical, etc.) to understand the interdependencies within the design. This ensures a holistic approach to problem-solving and design validation.
Simulation-driven design in practice
Imagine designing a complex automotive part, such as a suspension arm. The traditional approach would involve building a prototype, physically testing it, and then tweaking the design based on the results. With SDD, we can perform FEA to assess the structural integrity under various loads, CFD to understand how airflow affects heat dissipation, and thermal analysis to ensure the material doesn’t degrade under temperature fluctuations - all before a single prototype is created.
Moreover, for an engineer working in highly regulated industries like aerospace or medical devices, the ability to run complex simulations and provide detailed validation reports becomes critical in securing certifications and regulatory approval.
Tools for simulation-driven design
There are several leading software platforms used in the industry, including:
- PTC Creo: A powerful suite with embedded simulation tools that allow for easy integration of FEA and CFD during the design phase.
- ANSYS: Known for its advanced simulation capabilities, ANSYS provides robust solutions for structural, thermal, and electromagnetic analysis.
- Autodesk Fusion 360: Combines CAD, CAM, and CAE in a cloud-based platform, offering easy access to simulation features for small to medium-sized projects.
- SolidWorks: A widely used tool with a focus on mechanical engineering simulations, including stress analysis and vibration testing.
Challenges and future of SDD
While SDD offers immense benefits, it also comes with challenges. High upfront costs for software and training, the need for specialised knowledge in interpreting simulation data, and ensuring that simulations are as close to real-world conditions as possible can be barriers. However, as software becomes more intuitive and hardware improves, the accessibility of SDD is increasing, allowing more engineers to integrate it into their workflow.
Looking forward, advancements in AI and machine learning could further enhance SDD by automating more aspects of design optimisation, reducing the need for manual input, and even predicting potential design issues based on historical data. The growing trend towards digital twins - virtual models of physical products - will also further the reach and importance of simulation-driven design.
If you have a project that you think would benefit from SDD, please contact me. We use SOLIDWORKS to help design engineers find efficiencies, cost savings, and all the other benefits listed above. We seamlessly integrate with your team to ease the design process.
