CAE Industry Trends Empower Engineers to

Simulate Everything
Simulate a product’s lifecycle with the Cloud, Digital Twin, Multiphysics and More

By Shawn Wasserman
Simulation Editor, ENGINEERING.com

Disclaimer: The presentation was first presented at the ESI Forum but is vendor agnostic. Data was sourced
from various CAE vendors and previous materials from ENGINEERNG.com. Unless otherwise stated, all
opinions are mine— Shawn Wasserman.

You know, I wanted to start this presentation with a joke to lighten the mood. I spoke to my
manager and he’s a really conservative guy, right. He asked me to mitigate the risk so I ran a
few simulations first. After weeks setting it up, running optimization algorithms to find the best
joke possible, getting it all to converge. Turns out, after all of that the model said “Don’t start
a presentation with a joke.”

Hi Shawn Wasserman, here Simulation Editor at ENGINEERING.com. I’ve gone to dozens of

simulation conferences over the last few years and in that time I’ve interviewed hundreds of
big names and thinkers in the field, so I’ve picked up on a few trends in the industry. So to
prime us today for the rest of this conference, I figured I would discuss some of these industry
trends. Some I’m sure you’ve heard of. But chances are there is a trick or two up my sleeve
that will be news to you. So, let’s get started.

1
 We are Becoming a Simulation Society

We are becoming a simulation society. Practically since the first computers we have been
using them to simulate the world around us—from the earliest aeronautical and structural
problems, to the heat shield on Lockheed Martin’s Orion spacecraft, which you can see on the
lower left.

But simulation as an industry is growing far beyond the engineering applications. There are the
obvious weather models that are nearly as old as Finite Element Models. But the tools of the
trade are expanding, from the films we watch to virtual reality, either for entertainment or for
training purposes.

So, one of the key trends in simulation is that it is becoming democratized to the point where
people may not even know they are using it. But for the application of engineering, “Why
would we want more people using simulation?”

2
 “Better performing designs are achieved in
less time and at lower cost when a product is
informed by physics and engineering versus
preconceived organizational tenets of how a
product should evolve.”
-Simone Bonino, vice president of Marketing HyperWorks at Altair.

• Read Quote

In other words? Computer-aided engineering (or CAE) is necessary to stay ahead of, or on
par with the competition—and the more simulations you perform, the better off you will be.

3
 Simulation Is Becoming Ubiquitous: Simulate Everything

In a room full of simulation experts, I hardly need to tell you that physical testing is expensive.

But what people may not know is that simulation trends are making it possible to simulate
almost everything. This will help you reduce your physical testing requirements. This is thanks
to trends like improved multiphysics and HPC, GPU and cloud options to crunch all of these
numbers.

Using these and other tools, engineers will find it easier and easier to improve products
throughout their lifecycle by:
• Optimizing their designs,
• Catching design flaws early,
• And gathering real time information from products in the field using the digital twin
and IoT.

All of this is linchpinned by simulation.

4
 “Physical testing costs at least five to six
times the cost of product development
resources on vehicle projects. The only way
to meaningfully reduce the cost of physical
testing is with simulation.”
-Dominic Gallello, president of MSC Software.

None the less, physical testing remains a major verification method within engineering. This is
in part due to the fact that getting started in simulation traditionally had a major financial price.
However, these price points are dropping thanks to pay-as-you-go services, new licensing
models and cloud HPC.

But keep in mind:

Read quote.

5
 Simulation Is Becoming Ubiquitous: Simulate Everything

Now, simulation will never fully replace physical testing. However, the only time we use
physical testing should be to verify the simulation model and to verify the final design. As the
Captain Picard Meme says, The goal of simulation should be to ensure that the final design
prototype passes it’s physical testing the first time. Otherwise, your project will be plagued with
expensive late development redesigns.

6
 Everybody’s a User: You Don’t Have to be Boeing…

The reduced price point is only one way to democratize simulation. Tools are also becoming
easier to use as they streamline their workflows and graphical user interfaces. These
democratization tasks are having an interesting effect:

Everyone can become a simulation user.

Simulation isn’t just for rocket engineers who wrote a 500 page thesis that’s now collecting
dust somewhere. These days, simulation is for everyone from that NASA engineer, to
designers, to the kids in that FIRST Robotics competition, pictured here.

7
 Everybody’s an Analyst: You Don’t have to be Boeing…

Not only can almost everything be analyzed but now with the help of democratization everyone
is analyzing. Take the Boom! Team pictured here. It’s their goal to revive the concept of the
Concorde plane by offering supersonic travel to the everyday consumer. The only way to do
this and make it affordable for their team is with simulation.

8
 “Cloud computing can deliver CAE to the
masses with minimum investment. Start-ups
or small companies can access an incredible
deal of computing power to run demanding
simulations.”
–Dominique Lefebvre, head of Product Management at ESI Group

So, how is all this democratization taking place? First and foremost, there is cloud computing,
token based licensing and pay-as-you-go licensing. The point of these is to open up
simulation to small and medium businesses, or even to the individual. You don’t need a
supercomputer anymore; with some of the cloud-based simulation options out there, vendors
tell me that a thin client can do the trick.

Read quote

A lower entry point for software and HPC translates to more users.

And better yet, large businesses can still benefit from the cloud, particularly when performing a
rare simulation that is exceptionally large. They no longer have to bog down their in-house
HPC, or spring for a new one just for a one-time use.

9
 How is This Possible? Democratization with Simulation in-CAD

As for software, there are a few tools out there that are bringing simulation to more users. As
I’ve mentioned, these tools typically do this by streamlining workflows and offering intuitive
graphical user interfaces. This cuts down on the training needed to use these tools.

In respect to the realm of engineering, one of the biggest is simulation in-CAD. The idea is to
bring simulation within a CAD workflow and interface that is familiar to designers and design
engineers. This allows the training the user needs to focus on the physics as they will already
be capable to use the software.

There are a number of Simulation in-CAD examples, but pictured here we have PTC Creo
Simulate and IronCAD Multiphysics extension.

These tools may not have as much freedom and capabilities of a full simulation suite, but they
can typically do more than what your average designer or design engineer will need. The
downside to these tools is that for some will offer too big of a sandbox. The user needs to
have a significant understanding of physics to avoid the garbage-in garbage out phenomena.

10
 How is This Possible? Democratization with Engineering Design Platforms

Similar to simulation in-CAD are Engineering Design Platforms, such as 3DEXPERIENCE and
Autodesk 360.

These tools offer a much bigger sandbox. These platforms can link together a whole portfolio
of design software under one roof, on top of linking simulation and CAD, users might get
access to tools like CAM, PLM and more.

The platforms democratizing these tools by marrying and streamlining graphical user interfaces
until they all have a similar look and feel. This way when you are trained in one you can
muddle your way through the others assuming you understand their underlying functionality.

The benefit of these tools is that they generally offer means to store and manage files on the
cloud. This way no data is lost and versioning control is maintained.

They also tend to offer tools to promote collaboration from anywhere around the world.

However, these tools are much more expensive than simulation in-CAD, and suffer from the
same sandbox, garbage-in garbage-out issues.

11
 How is This Possible? Democratization with Simulation Apps

To alleviate these issues, companies have been developing simulation apps and templates.
You could say this is part of the app-ification trend going on in almost any industry, and the
idea isn’t much different with CAE.

The idea is to have your simulation expert make one particular simulation task so easy that
anyone can do it by filling in a few input fields. These tools can also be tailor made for your
systems and organization.

The programmers are then responsible to ensure that users can’t input any value or
combinations of values that break the logic of the system. With a good simulation analyst
creating your simulation app, you will gain a great tool for your organization.

Pictured here is an example of a COMSOL app.

By creating this, tool for your organization, an analyst can offload those simple yet common
simulations to others in the team and instead focus on the harder, more interesting stuff.
Additionally, if there is a simulation you need more people working on you can just make a
new app or add to the first one. The only limitation is that the parent Simulation Platform will

12
need to be able to perform this task.

The downside is that the analyst needs to find the time to make the app for your organization.

12
 How is This Possible? Democratization with Job Specific Simulation

If creating your own app will prove too time consuming then your simulation expert might
suggest to purchase a job specific simulation tool.

Similar to simulation apps, these are simulation tools targeted to a specific industry or job role,
but this time they are made by a vendor and not in-house.

To the left, we have ESI’s Virtual Seat Solution, and solidThinking Click2Cast on the right, but
there are so many examples here I could take up the whole presentation naming them.

These tools are typically more in-depth than a simulation app created in house as a whole
team of experts work on developing them. However, they lack that tailoring for your specific
organization. Their greatest downfall is that they lack any sort of sandbox. They are what the
vendor gives you, and if you want to perform a simulation not offered in the software then you
will need to wait and hope for an update, or buy a new software offering.

However, if you have a vertical within your organization that focuses on a handful of simulation
tasks, these tools can be a god-send. Particularly since they will be easy to learn as the
interface will be tailored to people in your industry.

13
 “The number of designers far outnumber the
number of CAE specialists, there’s a need to
explore strategies where more designers are
using simulation methods to help in the
design task.”
–Srinivasa Shankar, director of Global Simulation Product Marketing at Siemens PLM Software

So again, why should an engineer care about giving a designer the simulation reins? Well:

Read quote.

I can’t stress this enough, the earlier and more frequently your organization simulates, the better your
designs will be.

14
 Role of Analysts and Engineers with Democratization

So with all of this talk of non-engineers and non-experts doing simulation, you might be
wondering, “will these democratization tools be taking over your jobs?”

15
 Role of Analysts and Engineers with Democratization

Don’t panic. You don’t need to join ENGINEERING.com’s Job Board quite yet… Well, we
would like you to sign up to the ENGINEERING.com Job Board, but I’m saying you don’t
HAVE to. Simulation experts will still be needed.

After all, why was my wife insisting we hire a professional photographer to photograph your
wedding instead of my cousin with his SLR camera? Because you want it done right.

Who do you think will be building the simulation apps and templates? Who will be suggesting
the job-specific simulation tools to your purchasing team? It will be the people in this room.

Democratization of simulation will allow you to become a leader in your organization as you
train new users and build tools for simple CAE. You can also focus on simulation governance
to ensure best practices are met.

You will be freeing up your time as everyone else works on the small stuff. When an
impossible simulation comes around, they will know who to call.

16
 “Democratization will actually allow the
simulation experts to spend more time
on what is important, such as research
and development of new methods.”
— Nicolas Tillet, product portfolio manager for SOLIDWORKS Simulation

Don’t believe me? Let’s go back to the experts:

Read quote.

Simulation is still complex; take Multiphysics, for example.

Be the expert. Focus on the complex CAE and making sure your community of simulation
users know what they are doing. Learn about the tools out there that can help you simulate
everything.

17
 Tools to Simulate Everything: Multiphysics

So, now that you know you will need to be an expert in the small task of simulating everything, where
do you start? Besides, you know, everywhere.

The first place to look is actually an obvious location: multiphysics. This trend in simulation involves
the coupling of different physics to create a more complex yet accurate model. Multiphysics is the
backbone of simulating everything.

Naturally, these simulations are not small or easy. To crunch the numbers of a 3D multiphysics
simulation takes heavy HPC or cloud computing.

18
 Tools to Simulate Everything: The Cloud

Now, we’ve covered the cloud earlier, and how it can offer HPC at affordable rates. What I
didn’t mention is the fact that often these HPC resources can be used on a pay-as-you-go
model, on-premise or off-premise depending on the security needs of your organization.

If you take the full plunge into the Cloud you can also allow your organization to simplify their
hardware and software options. Vendors are saying that with the cloud thin clients will do.
Some vendors will offer their complete portfolio on a token-based licensing system—those
Engineering Design Platforms I mentioned.

Just be sure to look for tools that focus on collaboration if you are taking the full plunge.

19
 Tools to Simulate Everything: IoT, Digital Twin, AR & VR

Now I’m going to do something controversial here by lumping the AR/VR, the Digital Twin and the
Internet of Things together in this slide. This is because in many ways, they are all sides of one
tetrahedron.

The Internet of Things and Digital Twin brings continuous simulation into reality by linking your models
to real-world and real time data. The IoT captures real life data that is then used as inputs for
simulations to drive future designs, preventative maintenance, new monetization options, and the
discovery of new use cases.

By combining the digital twin and IoT with AR/VR, we can

start to explore these designs in a virtual space.

It’s the next logical progression. For instance, why stop at

the IoT and digital twin telling you a motor has broken
down? Why not have that trigger a video on a mechanic’s

20
AR/VR display showing them how to replace that motor in
the space they will be working in?

This is certainly a concept talked about already today

during the keynotes.

20
 Tools to Simulate Everything: Generative Design

Now that you’ve collected your real-world data, chances are you’ve discovered that your product is
being used in a way you never expected. These new loads will call for new optimizations of your
designs.

I know of a great anecdote from an IoT specials that was telling me that an international
company was selling IoT dishwashers around the world. They found in one country that people
kept turning on the dishwashers before dinner instead of after dinner like everywhere else.

After they investigated it turns out people were cooking fish in their dishwashers! This wasn’t
just a potential opportunity for the marketing team to sell dishwashers that “cook fish better
than anyone else.” It was also potential opportunity for the engineers to designs to not only
clean dishes but to cook fish to a safe temperature.

When that time comes, you may want to look into generative design tools, like the solidThinking
Inspire topology optimization pictured here. This tool focuses on structural optimizations when cooking
that fish will focus on heat transfer and CFD but the concept is the same. For solidThinking’s Inspire
all you do is input your loads, constraints and design space and grow a semi-optimized shape as if
from thin air. It’s rather magical.

21
This particular tool is based off of a bone growth algorithm, but other optimization tools, like one I will
mention shortly, exist based on genetic and many other algorithms. This typically leads to more organic
looking designs that will make your customers marvel at their functionality and beauty.

21
 Tools to Simulate Everything: Design Space Optimization

Related to generative design is the concept of design space optimization. This is more of a multi-
parameter approach to the optimization, and will therefore create more global optima.

They take a considerable amount of number crunching, but have some tricks up their sleeves. Look
for options that can transform your 3D models into 1D models using characterization functions and
response surface models.

22
 Tools to Simulate Everything: 3D Printing

Now, topology optimization and general optimization tools have technically been around for a long
time, so calling them a trend might make some heads turn.

However, these tools are starting to pick up steam thanks to the trend of 3D Printing. You see, those
designs were much harder to build with traditional manufacturing, but with 3D printing many of them
are now possible.

Do you need to prototype anyway? Why not make it in style—and with less labour—by using a 3D
printer?

Or why not manufacture a small run product with 3DP? In this case I just had a great conversation
during lunch and there are options on the way to simulate the 3D printing process so you can find the
internal stresses in your product. Currently, there are customers working simulation experts to model
this on a per run basis. But it’s only a matter of time until full 3D Printing simulation tools become
reality.

23
 Tools to Simulate Everything: Crash Test Dummies

Another important thing to simulate is human interactions. There are plenty of tools out there now that
can input a digital human into your designs and see how they will react—be it in a safety test, comfort
test or workflow optimization.

One thing is for sure: the automotive industry is saving a lot of money using tools like this to reduce
the scrap prototype cars and seat they design.

24
 Tools to Simulate Everything: Composites and As Manufactured Simulations

Finally there are the ever popular composites. These materials need to be tested rigorously, as
their manufacturing heavily affects their strength.

It’s always important to remember that your product is never “as designed”, it’s “as
manufactured.” Simulate accordingly!

For composites this is law, not a suggestion. Therefore, when working with composites, stay
away from global averages. Simulate that manufacturing process, and find out how those
fibres are really oriented. Only then will you know your parts true strength.

25
 “There are no general capabilities an
engineering firm needs in a CAE software. It
depends on their specific needs, requirements
and the type of structures they are designing
or analyzing.”
–Dr. Jan Cervenka, Founder of Cervenka Consulting

Last but not least, remember this:

Read the quote.

Do your research and find out not just what you need today, but what trends you need to pay
attention to so you can stay ahead of the competition tomorrow.

26
 Things to Consider When Looking for Simulation Software
Does the software:
• Perform all the assessments you need and will need?
• Have good customer support/user forums?
• Converge, offer error approximations and correlate to physical tests of your use cases?
• Provide easy-to-use user interface (UI), meshing and pre/post processing?
• Integrate third party computer-aided design (CAD), CAE, computer-aided manufacturing (CAM) and product lifecycle
management (PLM)?
• Scale solvers with high performance computing (HPC) and Cloud?
• Offer multiphysics/multi-loading?
• Have tools for optimization, design space exploration and/or generative design?
• Have material and failure mode databases?
• Offer flexible licensing?

Now, with all of this talk of things you can simulate, you might be thinking about getting your hands
on new CAE software. Before you do, check out this list of questions you might want to consider or
ask a vendor about their simulation tools.

There may not be any general CAE capacities everyone will need, but these questions will get you on
the right path to finding what you need.

Now I know you aren’t reading this. Who am I kidding?

Take a picture of this, or grab it from ENGINEERING.com. I’ll be publishing these slides after the
conference.

*wait for photos*

27
 Learn more about simulation
at ENGINEERING.com

Thank you for your time

Questions?

Contact and follow me at:

• Email: [email protected]
• Twitter: @ShawnWassserman
• LinkedIn: www.linkedin.com/in/esjw1/
• Articles: www.engineering.com/Author/ID/195959/ShawnWasserman

With that, thanks for your time and I hope you enjoyed my presentation.

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29
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-Safer-More-Comfortable-Functional-Seating.aspx

26. http://www.engineering.com/DesignSoftware/DesignSoftwareArticles/ArticleID/15027/Simula
te-Composite-Thermoforming-to-Avoid-Defects-Early-in-Development.aspx

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