Finite Element Analysis Is Not a Magic Tool

Finite Element Analysis (FEA) is one of the most powerful tools in modern engineering. It helps shorten product development cycles, reduce costs, and improve performance. But FEA is often misunderstood — and when misused, it can create serious problems. Cheap or inexperienced analysis doesn’t save money; it usually wastes it.

The Myth of “Cheap” FEA

Too often, companies assume that FEA is a push-button solution. They look for low hourly rates overseas or assign complex simulations to inexperienced analysts. The result? Designs that look good on paper but fail in practice.

One company outsourced FEA overseas, where designers ignored “design for assembly and manufacturing” procedures. The result was a design that was impossible to build cost-effectively. Every hour spent on that analysis was wasted.

Managerial Pressure and Bad Decisions

Poor FEA can also slip through due to internal pressure. In one case, an engineer flagged serious flaws in outsourced analysis. His supervisor told him to accept it anyway. The engineer refused and resigned.

Why Experience Matters in FEA

FEA is not just about running software — it requires engineering judgment. A recent graduate once performed structural analysis for a new product. The first prototype failed in testing. A senior analyst later reviewed the work and found basic mistakes that no experienced engineer would have made. The company thought it was saving money, but instead wasted resources on failed builds.

FEA as Part of a Complete Process

The truth is simple:

• FEA is a powerful tool when used by skilled analysts.

• Prototyping and testing are still essential to validate results.

• Cutting corners in analysis costs more later in failed prototypes, redesigns, and lost time.

Conclusion

Finite Element Analysis is not a magic wand. It accelerates development and reduces costs only when performed by experienced professionals — and when paired with physical testing. Companies that chase “cheap” analysis may save a little upfront but risk wasting much more in the long run.

FEA done right saves time, money, and frustration. FEA done wrong multiplies risk.

Norman T.  Neher, P.E.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org