Structural simulations for all types of products
Structural simulations for all types of products, including static and dynamic analyses in both linear and nonlinear regimes. We evaluate structural behavior under various loads: forces, pressures, accelerations, or temperature gradients. Nonlinear effects such as structural instability, contact, and material plasticity are accurately modeled. Fatigue life prediction is based on realistic load histories and material response. These solutions apply across industries, from automotive and aerospace to industrial equipment.
110 kHz @ 2.5 kA induction heating system
Calculate forces, displacement, stresses and strains.
Load Capacity Assessment
Reduce or eliminate prototype testing
Solver: ANSYS Mechanical
Material definition: Non-linear material properties
Physics coverage: capable of capturing key physics characteristic and phenomena such as material failure, large deformations, complex contact occurrences
Cost savings form avoided physical tests (5-20K/test)
Rapid design iterations and modifications without the time and cost constraints associated with physical prototypes.
Cost and time effective product development processes.
Transient analysis for conveyer
Calculate the deflection of the conveyer under the load while moving along the production line.
Design conveyor systems that operate smoothly, efficiently, and reliably under varying operating conditions to ensure safe operation
Reduce or eliminate prototype testing
Solver: ANSYS Mechanical
Physics coverage: capable of capturing key physics characteristic and phenomena during movement
Pre-process: mid-plane surfaces to reduce solution time and to easily change thickness
Cost savings form avoided physical tests (10-30K/test)
Eliminate scheduling conflicts for prototype vehicle testing and meet program deadlines ahead of time.
Reduced Product Development time and increase product life
Detent static analysis
Simulate rotation to calculate the torque, displacements, stresses and strain in the detent.
Reduce workflow and improve predictability.
Reduce or eliminate prototype testing.
Solver: ANSYS Mechanical
Material definition: Non-linear material properties
Physics coverage: capable of capturing key physics characteristic and phenomena during rotation.
Cost savings form avoided physical tests
Performance prediction
Optimized design, ensuring smooth operation, long-term durability, and minimal maintenance requirements.
Car Trailer, Loaded (RAR Homologation)
Design Precision: One of the primary goals is to achieve a high level of design accuracy and precision in the creation of complex 3D models that must be finely tuned to meet safety, performance, and regulatory standards (ISO 7641/2012) Calculate the displacements and stresses in the drawbar assembly when the trailer is subjected to a force of 4620 N, applied at three different angles relative to the longitudinal axis of the trailer.
Solver: Tet + Hex Meshing combination to handle the very complex geometry while preserving accuracy (Ansys Meshing).
Complex design and features with multiple moving parts, using kinematics to see the ergonomics of the different interior parts, analyzing different positions and scenarios to develop an optimized and ergonomic product.
Complex surface modeling followed by part/ assembly simulations
Improved Safety: Simulation can identify potential safety issues and vulnerabilities in vehicle designs, helping engineers make necessary improvements before physical production.
Reduced physical prototype testing, avoided late-stage design and tooling changes.
Oven child lock mechanism
Evaluate behavior of oven lock mechanism.
Ability to prevent accidentally door opening, reaction forces, deformation, stress and strain level were evaluated.
Calculate the stress and strain in the door lock components (bracket) under operating force (pull force > 90N).
Ansys Mechanical used for complex Static Structural/Transient simulations.
Large Deflection, Complex Contact status and multistep analysis considered.
Step 1 – In a point located on the door, an imposed displacement of -3.5 mm was applied along Y axis (to open the door);
Step 2 – In the same point, an imposed displacement of 0 was applied along Y axis (to close the door).
During these 2 steps, the reaction force was calculated in the point located on the door as well as the stress and strain into the bracket and plastic clip.
Results for the pastic clip, for the bracket and for the whole mechanism.
Ability to evaluate door lock safety function for children safety reasons by reducing physical tests and reducing design time.
Conclusion of this study: mechanical door lock will pass the pull force (90 N) test.
Customer saved 4 weeks of testing and about 30k euros.
Static analysis for Halo Lamp – Lens insertion
Calculate forces, displacement, stresses and strains
Load Capacity Assessment
Reduce or eliminate prototype testing
Ensure that the push-in force is small enough to have the lens pushed by hand
Solver: ANSYS Mechanical
Material definition: Non-linear material properties
Physics coverage: capable of capturing key physics characteristic and phenomena such as material failure, large deformations, complex contact occurrences
Cost savings form avoided physical tests (5-20K/test)
Rapid design iterations and modifications without the time and cost constraints associated with physical prototypes.
Cost and time effective product development processes
Static studies – contact analyses
Calculate forces, displacement, stresses and strains to establish the proper shape of heat steaks
Load Capacity Assessment
Reduce or eliminate prototype testing
Solver: ANSYS Mechanical
Material definition: Non-linear material properties
Physics coverage: capable of capturing key physics characteristic and phenomena such as material failure, large deformations, complex contact occurrences
High-fidelity meshing and FEA results ensure accurate modeling of stress concentration zones
Stress results highlight critical regions, enabling geometry refinement or material redistribution to prevent failure
Accelerates development timelines and lowers iteration costs
Life predictions for electronic hardware
Check the reliability of the PCB assembly when subjected to thermal loads and vibration profiles.
Reduce workflow and improve predictability.
Reduce or eliminate prototype testing.
Solver: ANSYS Sherlock and ANSYS Workbench
Part Library: Sherlock part libraries contain over one million parts.
Physics coverage: capable of capturing key physics characteristic and phenomena by combining ANSYS Sherlock and ANSYS Workbench capabilities
Cost savings form avoided physical tests (~50K/test)
Eliminate scheduling conflicts for prototype vehicle testing and meet program deadlines ahead of time.
Achieve high-confidence in 100% virtual validation with CAE models for future programs
Structural dynamic analyses for Proba 3 satellite subassembly
Making sure the critical equipment (Focal Plane assembly) of the Proba3 mission can withstand the dynamic loads experienced during transportation and during the rocket launch.
Making sure the sensitive components of the equipment can still function within the specifications under the thermal loads experienced in the Earth orbit.
Solver: MSC Nastran; Highly accurate Test-FE correlation!
Physics: Static structural; Modal; Random vibrations; Transient response; Thermo-Elastic
Validation thru simulation of the studied equipment.
Generation of a superelement model to be used in the larger assembly analyses.
Component level FE models
Build light weight (minimum DOFs) fully detailed EV and ICE powertrain FE models.
Optimum number of nodes and elements to ensure accuracy of results vs. running time.
Extensive experience in handling complex assemblies using Hypermesh as pre/processor.
Embed engineering data into the models.
Accurate definition of mass and inertia, stiffness and damping.
“Excite ready” FE models.
Customer only runs the models, no need for other pre/process work
Static nonlinear analysis – pushing of a button
Calculate displacements, stresses and strains that occurs during a sphere test
Load Capacity Assessment
Reduce or eliminate prototype testing
Solver: ANSYS Mechanical
Material definition: Non-linear material properties
Physics coverage: capable of capturing key physics characteristic and phenomena during the test
Full subsystem evaluation ensures all interfacing parts meet performance under the test.
Helps verify load transfer paths and detect potential failure in hidden or complex regions.
Detailed deformation and stress results assist in quantifying safety margins and assessing component compliance with standards.
Minimizes the need for overdesign.
Enables rapid virtual iteration and testing of design changes, saving time and cost over trial-and-error physical testing
Vibration for automotive converter
Electronic product behavior at unexpected vibrational loads.
Ansys Structural Modal and Harmonic simulations were conducted.
Natural frequency and shapes were investigated.
Vibration characteristic of the PCB and Housing assembly was evaluated.
Capacitors displacements and their solder joints with PCB was evaluated.
Validates structural integrity under operational loading, preventing costly field failures.
Early detection of potential failure points.
In this way we were able to see if the product is reliable at roading conditions.
Reduces the need for extensive physical prototypes, thanks to virtual validation through simulation.
