Why Every Engineer Should Use Simulation in Product Design

The Evolution of Simulation in Engineering

During Industry 3.0 (1960s-2010s), computers and 3D CAD capabilities became more powerful and accessible.

As 3D systems evolved from mainframe workstations to personal computers, virtual testing and simulations became essential for large-scale manufacturers and the broader market.

Finite Element Analysis (FEA) software expanded to create digital models and simulate performance under various conditions.

This advancement enabled engineers entering Industry 4.0 to test 3D designs for different failure modes, streamlining the design validation process.

The Shift from Physical to Virtual Testing

Ensuring compliance with industry regulations is critical as engineering evolves. Emerging technologies reshape regulatory frameworks, pushing engineers to adopt advanced validation methods.

The limitations of physical testing often resulted in time-consuming modifications and delays and engineers are increasingly shifting toward virtual prototyping and digital twins, which allow for validation without extensive physical prototypes, reducing costs and design timelines.

Simulation technologies enable engineers to conduct numerous tests simultaneously, explore various design scenarios, and model extreme conditions. This ensures safety and industry standards compliance before production and accelerates development cycles.

The advantages include faster time-to-market, cost savings, greater design exploration, and enhanced accuracy.

The Key Benefits of Simulation in Product Design

Reduce Costs and Time-to-Market

Simulation technologies transform engineering design by enabling digital testing of real-world conditions. This innovation eliminates the need for repeated prototyping, allowing engineers to make informed decisions early, significantly reducing design cycles and accelerating time-to-market.

By optimising designs before manufacturing, companies save on material costs and increase efficiency by testing multiple variations simultaneously. This approach minimises production delays by identifying potential flaws ahead of fabrication.

SOLIDWORKS Simulation empowers engineers to explore "what if?" scenarios, thoroughly optimising designs before creating the first physical prototype.

Increased Design Confidence and Reduced Risk

Engineers face complex design challenges, including managing documentation overload and ensuring compatibility with new technologies.

Effective coordination across departments is crucial. Simulation offers a structured and repeatable approach to evaluating designs, reducing risk, and enhancing confidence during the final approval.

This is especially critical in aerospace and medical devices industries, where the costs and time taken for physical testing can be prohibitive, so leveraging simulation is essential for ensuring successful design outcomes within realistic timeframes.

Why SOLIDWORKS Simulation?

SOLIDWORKS Simulation is a leading virtual testing platform that integrates seamlessly with CAD, removing the need for external software.

It features advanced material models that enable engineers to evaluate components under various stresses, impacts, and environmental conditions. SOLIDWORKS Simulation offers a comprehensive portfolio of analyses, including static, dynamic, thermal, and nonlinear assessments.

SOLIDWORKS Simulation Packages and Capabilities

SOLIDWORKS Simulation Standard

SOLIDWORKS Simulation Standard is an intuitive virtual testing environment for static linear and time-based motion, enabling concurrent engineering to assess product performance and longevity during the design phase.

SOLIDWORKS Simulation Professional

SOLIDWORKS Simulation Professional allows you to optimise designs, assess mechanical resistance, ensure durability, and analyse topology, natural frequencies, heat transfer, and buckling. It also performs sequential multi-physics and high-cycle fatigue simulations.

SOLIDWORKS Simulation Premium

SOLIDWORKS Simulation Premium enables efficient evaluation of designs for non-linear and dynamic responses, dynamic loading, and composite materials. It includes three advanced studies: Non-Linear Static, Non-Linear Dynamic, and Linear Dynamics.

Real-World Applications of SOLIDWORKS Simulation

Various industries, including automotive and consumer electronics, use simulation techniques to enhance their processes.

This approach optimises material usage while ensuring product integrity and validating complex assemblies before manufacturing.

By leveraging simulation, companies can meet regulatory compliance requirements without extensive physical testing.

For instance, automotive engineers can use topology optimisation simulations to design lightweight components that maintain strength, reducing overall weight. Electronics manufacturers can conduct thermal analysis to enhance cooling efficiency, addressing potential overheating issues.

Conclusion

Simulation has revolutionised product design by enabling engineers to test, validate, and optimise their ideas in a virtual environment.

Tools like SOLIDWORKS Simulation help engineers stay competitive in an evolving industry by reducing costs, improving product reliability, and increasing design confidence.

Whether you're streamlining design validation, enhancing performance, or mitigating risk, integrating simulation into your workflow is essential.