Simulation-Driven Design: Product Development

Blog • CAD & Simulation

What Is Simulation-Driven Design (SDD)?

Simulation software has existed for decades, but its potential was often limited to analysts with access to high-powered computing. Traditionally, simulations occurred late in the design process, just before final prototyping—when most costs were already locked in. These simulations, often taking weeks, created a critical juncture; discovering a significant flaw meant restarting the entire development process.

Simulation-Driven Design (SDD) transforms this approach by integrating simulation tools throughout the design lifecycle. Leveraging their combined expertise in finite-element analysis and CAD, Ansys and PTC bring over a century of innovation to SDD. This methodology delivers clear advantages: reduced costs, improved quality, and faster time-to-market.

Unlike traditional methods, SDD enables design engineers to evaluate multiple design alternatives, predict real-world performance, and address risks early. The process democratizes simulation, giving design teams the tools and insights to drive efficiency and innovation. AI-driven generative design technology enhances this approach by exploring vast design possibilities based on specific constraints and goals, often uncovering solutions beyond a designer’s imagination.

Embedding simulation directly into CAD tools allows design engineers to test scenarios, iterate quickly, and refine models automatically. This seamless process frees simulation experts to tackle complex challenges, optimize resources, and foster innovation throughout the product development journey.

PTC and Ansys share a unified vision: helping organizations revolutionize product design through real-time, high-fidelity simulation tools. By combining Ansys technology with Creo, this partnership provides design engineers with unmatched capabilities. Engineers can now access instant design guidance, eliminating the delays typically associated with design-simulation feedback loops. Additionally, high-fidelity simulations seamlessly integrated into Creo make advanced tools easy to use and accessible throughout the design process.

This collaboration goes beyond simulation tools. Integrated capabilities within Creo enable smoother workflows, fostering collaboration between design engineers and analysts. By connecting PLM systems, materials management platforms, and the Ansys and PTC ecosystems, organizations streamline data exchange and simplify processes. These integrations enhance collaboration and empower stakeholders to make informed decisions at every stage of the product lifecycle.

The traditional product development cycle has long been plagued by challenges, including reliance on physical testing for validation. By shifting simulation earlier in the process, engineers can explore multiple designs, improving performance, reducing costs, and accelerating time-to-market.

Simulation-Driven Design Cycle

During the conceptual phase, generative design plays a pivotal role by automatically optimizing part designs based on constraints and objectives. This strategic tool considers factors like weight, material selection, manufacturing processes, and “keep-out” regions. As demand grows for products that are lighter, faster, and more durable at lower costs, engineers must iterate quickly.

Real-time simulation tools, integrated directly into the Creo environment, provide immediate feedback on design choices. Engineers can test structural strength, thermal effects, modal frequencies, and fluid dynamics without switching platforms or converting files. This streamlined approach saves time and empowers teams to confidently explore design options. Early validation with real-time simulation helps avoid potential issues, reducing delays and time-to-market while optimizing analyst resources and lowering development costs.

Creo’s real-time simulation capabilities go further by offering linear static structural analysis, modal structural analysis, and steady-state thermal analysis. Engineers gain accurate insights into deformation, stress, strain, temperature distribution, vibration modes, and resonance frequencies. Automated analysis setups, mesh creation, and Ansys simulation solvers ensure reliability, while advanced features like non-linear contact and combined structural-thermal analysis add even more flexibility.

By correlating simulation results with functional testing, design engineers can streamline final product qualification and production readiness. This integration ensures a seamless process, delivering validated designs faster and more efficiently.

Implementing simulation tools effectively involves more than acquiring technology—it demands a shift in organizational processes. Integrating simulation reviews earlier in the design cycle empowers design engineers to harness these tools to their full potential.

This transformation also requires analysts to step into coaching roles, guiding teams in adopting simulation technologies and establishing best practices across the organization.

Collaboration between analysts and designers unlocks greater product insights. Designers can utilize generative design and real-time design guidance, while analysts focus on complex validation studies.

This dynamic boosts productivity and enhances product quality, making analysts even more valuable contributors.

However, successful adoption goes beyond technical capabilities. It requires a cultural shift toward embracing innovation and continuous improvement. Just as with AI, these tools don’t replace engineers but amplify their skills and productivity.

By integrating these advanced technologies, organizations empower their teams to excel in their roles and drive meaningful innovation across the board.

Design engineers and simulation analysts are critical in driving sustainability within their organizations. Their responsibilities are expanding as they integrate advanced simulation and generative design technologies.

Engineers can now evaluate material choices for structural performance and environmental factors like energy consumption and emissions.

As sustainability considerations grow more complex, design teams need advanced digital tools to make informed decisions and manage trade-offs effectively. Companies like PTC and Ansys are addressing this need by enhancing their tools to tackle the increasing complexity of engineering challenges.

Engineers can exceed baseline sustainability requirements by adopting flexible workflows and innovative solutions. “We are excited to pursue more integrated materials management and sustainability workflows with PTC, building on the existing Ansys Granta connections to Creo and Windchill,” said Mark Hindsbo, Vice President and General Manager of Product at Ansys.

These workflows empower engineers to balance performance and environmental priorities, providing accurate, traceable, and reliable information on materials across enterprises.

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