Simulation-Driven Product Development

Design Models as the Starting Point

In modern engineering, design models are the foundation of simulation-driven product development. These models may be detailed 3D CAD representations or simplified geometries that preserve key features for finite element analysis (FEA).

Using the same geometry from design to manufacturing reduces translation errors and improves accuracy. For electronic systems, this may involve importing Gerber files and conductive trace layouts, which help estimate circuit board conductivity and thermal behavior.

Test Computationally, Then Build Prototypes

Finite element analysis allows engineers to virtually test CAD models before creating physical prototypes. This minimizes costs, speeds up development, and improves confidence in performance.

Simulation can evaluate:

• Heat transfer & thermal stress

• Impact and crash behavior

• Power dissipation in electronics

• Aerodynamic and fluid loads

• Dynamic performance (vibration, fatigue, noise)

By replicating real-world conditions digitally, engineers can eliminate multiple prototype cycles and focus physical testing where it matters most.

Why It Matters

Industries such as aerospace demonstrate the power of simulation-driven design. New aircraft undergo extensive computer modeling and FEA long before factory tooling or prototypes are built. This approach dramatically reduces cost compared to older methods that relied on 2D drawings, manual equations, and repeated physical testing.

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