Top 5 CAD Design Time-Savers for FEA Simulation

After decades in new product design, Brian Leadingham, President of Design Department, has learned that there are a handful of crucial things you can do when preparing your CAD models for simulation which can shave days or even weeks from the design schedule. Relying on inefficient, messy models is the quickest way to create bottlenecks in your analysis pipeline, forcing engineers to spend frustrating hours debugging geometry instead of analyzing performance. The secret to fast, reliable results lies not just in the simulation software itself, but in the efficiency of your CAD workflow.

Here are five disciplined habits that keep our simulation integration efficient and reliable, allowing us to move from concept to validated result faster than ever:

Five Habits for Efficient FEA Simulation

1. Clean Models First

Make sure you are using clean models by eliminating geometry errors and using simple geometry whenever possible. Complex interfaces can result in geometry errors, which are a major headache when meshing the model for finite element analysis (FEA). A clean model is the foundation of a successful simulation. This dedication to CAD efficiency prevents costly analysis failures down the line.

2. Separate Parts by Function

Separating parts in your model that will be the focus of investigation and optimization will make it easier to iterate quickly. Even if your component will eventually be molded as one piece, if it has two different functions (e.g., load transmission and spring action), it may be beneficial to temporarily separate it into two components for FEA. This simplifies the analysis and aids design workflow.

3. Check Units — Twice

A 1 mm vs. 1 inch mistake wastes precious time and will invalidate your entire analysis. It’s easy to overlook units when we are all constantly working in both SI and English systems. Before hitting "run," quickly verify that your CAD units, material properties, and load inputs are all consistent. This simple check is a powerful CAD efficiency habit.

4. Start Simple

Start with a simple model first. This will allow you to quickly refine your boundary conditions and loading setup. Once the simulation protocol has been established and validated with simple geometry, then you can bring forward the more complex geometry with confidence.

5. Validate Results

FEA simulation is incredibly powerful, but having some level of connection to reality will drastically increase your confidence. If at all possible, have at least one physical test correlation available to validate your simulation model. This grounding step confirms your simulation integration is accurate and reliable.

We recently used elements of this process on a complex injection-molded assembly for a great client. The assembly had multiple functions: load transmission, product activation, and cosmetic considerations. By stepping through the device with a disciplined simulation approach, we were able to correct two known issues and identify and resolve two previously unknown issues, keeping the project on track. Smart engineering starts with smart preparation.

Ready to Streamline Your Design Process?

What’s your go-to trick for keeping CAD plus simulation efficient? Partner with Design Department today to optimize your design workflow and maximize your CAD efficiency for FEA.