W H I T E P A P E R

Engineering Design,
Simulation, and Shape
Optimization
Introducing a Modern Design-Simulate-Optimize
Workflow in the Product Development Cycle
Table of contents
2 Executive Summary
4 End-to-end Shape Optimization
6 Traditional Versus Cloud-native CAD
9 Engineering Simulation in the Cloud
12 Objective-driven Optimization
15 Conclusions

Executive Summary

In this whitepaper, specialists from As components, parts, devices,

Onshape, SimScale, and ESTECO cover and products are expected to last longer,
the implementation of a design-simulate- perform better, be updated faster, and cost
optimize workflow relying on tools less, engineers are faced with increasingly
built on the latest cloud computing and complex design challenges that were
optimization technologies, applied to the unimaginable only a decade ago.
design of a centrifugal fluid pump.

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 Executive Summary

Adopting a modern workflow in for speed and accuracy, reduced wrangling

the product development cycle liberates of massive datasets, enhanced version
designers and engineers from legacy management, ease of use, 24/7 availability
software constraints and hardware of engineering simulation and optimization
limitations resulting in less physical software from anywhere.
prototyping, mass-customized products,
Case study: A real-world case featuring
and budget optimization.
the design optimization of a centrifugal
Key topics: Collaboration with distributed pump is discussed.
teams and customers, scalability needed

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End-to-end Shape Optimization

What do we mean when we talk about an model parametric iteration is generated in

end-to-end shape optimization workflow? the cloud in Onshape and then simulated
Let’s take a look at how geometry/shape in the cloud in SimScale. SimScale is
optimization can be used in conjunction used to perform an incompressible
with Computational Fluid Dynamics (CFD) CFD analysis on each parametric model
simulation to optimize a centrifugal with the respective simulation results
pump design. further analyzed in ESTECO’s VOLTA and
modeFRONTIER. This objective-driven
The simulation workflow starts with
optimization step intelligently chooses
a mechanical CAD model, which is
which parameters to change and optimizes
designed in Onshape. The model is
the design for maximum efficiency.
parameterized with seven geometric
parameters that can be altered. Each CAD

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 End-to-end Shape Optimization

CAD Parameters

CAD Results

End-to-end shape optimization workflow including a parametric feedback loop driving design
and simulation iterations.

This workflow includes a feedback loop. of computing in the cloud, only 65 of those
Using ESTECO’s tools, we can then select geometries have to be simulated to get to
which parameters to alter to optimize the the optimal result. In fact, all of those 65
design, and then the next geometry will be geometries are simulated in parallel using
generated in Onshape and run in SimScale. SimScale.
For this specific use case, we have seven
All of this can be efficiently and effectively
parameters that, for the sake of example,
achieved end-to-end by running cloud-
can take 10 values each. That would give
native Onshape CAD and SimScale CAE
us a matrix of 1 million simulations that
while they’re being orchestrated, and
we would have to run to analyze the whole
optimized, via VOLTA and ModeFRONTIER.
design space. By introducing a feedback
loop that leverages the capabilities

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Traditional Versus Cloud-native CAD

Advantages of Adopting SaaS Tools

Traditional, on-premise software places Then the software needs to be

the responsibility of hardware and its downloaded, installed, configured,
administration on the organization. This licensed, and updated several times
can add up if companies need to maintain a year on every server and every client
multiple servers, networks, firewalls, VPN, workstation. If your company operates
and disaster recovery plans. Server rooms across multiple sites, expect these efforts
require adequate power, cooling, fire (and challenges) to grow in magnitude.
protection, and physical security.

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 Traditional Versus Cloud-native CAD

With the above in mind, many companies With a SaaS platform, all data processing
are implementing a cloud-first strategy to operations are carried out remotely
streamline business operations, improve in the cloud. No data is transmitted or
employee productivity, drive cost savings, downloaded locally to any user’s computer,
and keep the company competitive. keeping sensitive data secure at all times.
Moving to the cloud saves significant SaaS applications implement security
amounts of time and money. SaaS tools measures that go way beyond what most
provide an immediate impact on: companies are able to implement or afford
on their own.
• Scalability
• Security Cloud-native Product Development
• Profitability
Onshape offers a cloud-native product
• Reliability
development solution that integrates CAD,
In addition to the added business benefits, data management, and analytics in one
using a SaaS platform means instant access platform. The goal is to let designers and
to all project data from anywhere in the engineers access their design documents
world. It also means: and collaborate from anywhere, on any
device, including tablets and smartphones.
• Not worrying about having the right
Version-control issues and data loss
software installed
common to file-based CAD are eliminated,
• Not being tethered to a desk
enabling teams to accelerate time to
• Being able to share data with others
market, and delight their customers.
rather than copying and emailing
• Being able to collaborate in real-time
with your coworkers

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 Traditional Versus Cloud-native CAD

The setup of the end-to-end shape optimization algorithm and simulating

optimization of a pump design use case them rapidly to find the most optimal
discussed in this whitepaper leverages solution is achieved with ease and speed.
the cloud-native architecture and API that In this use case, each simulation took
Onshape, SimScale, and ESTECO offer. approximately 5 minutes compared
In fact, automatically iterating through to upwards of an hour on a typical desktop
different configurations driven by an machine.

The centrifugal pump geometry is shown in Onshape, with the seven geometric parameters shown
in the Configurations section on the left-hand side.

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Engineering Simulation in the Cloud

Limitations of Traditional Simulation Versus Cloud-native

In addition to the limitations of traditional and evolved into complex UI’s that differ
CAD software, CAE software users face considerably between physics & solvers.
a few additional problems, such as the This represents a learning barrier to
high performance computing (HPC) new and/or inexperienced users who are
hardware that has to be purchased and unable to leverage and maximize the value
maintained, together with the relatively from these tools.
high fixed costs for the licensed seats of
For these reasons, simulation has
the simulation software. There may also be
a much bigger potential to create value
middleware required for scheduling solver
than currently realized with the biggest
jobs on a high performance cluster, plus
challenge being technical and economical
training and support for the users.
accessibility for engineers and designers
In most cases, traditional simulation tools who need it. Being a cloud-native CAE
were developed for specialists to use, software, SimScale achieves the level

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 Engineering Simulation in the Cloud

of accessibility required to truly lower the CAE infrastructure and processes, the
barrier to the adoption of simulation by benefits of adopting a cloud-native
vertically integrating the whole simulation solution include shipping better products
stack and making it accessible both faster at less cost thanks to the ability to
programmatically and graphically. From introduce simulation earlier in the R&D
the HPC infrastructure layer over data cycle, apply it to more applications, and
management to numerical methods explore the design space as needed. All
to physics and applications, this is not of this without requiring a stellar budget.
just an incremental step toward a better Let’s elaborate on the benefits in the
experience. For customers with existing following paragraphs.

Benefits of Adopting Cloud-native CAE

With reference to the end-to-end shape Platform Integration with Third-Party

optimization workflow discussed in this Technology: In this use case, the engineers
whitepaper, the main benefits of adopting needed to perform CFD simulations
a could-native CAE solution are as follow: while requiring tight integration with
their preferred CAD solution, Onshape,
Collaboration: On many projects
and the powerful design optimization
and/or projects involving many teams,
tools by ESTECO. The SimScale platform
both at the same office or geographically
provides an API layer that allows
distributed, it is key that the team can
access to all of the different physics and
collaborate effectively. SimScale is a SaaS
simulation capabilities in addition to
application that’s fully collaborative.
geometric parameters and even the UI.
There’s no exchange of large CAD models
Engineers can use Onshape to generate
or large simulation data files and users can
their geometry which is then passed into
simply log in to the same project and work
SimScale for the CFD simulation, with
together because everything is stored,
the results fed directly through
managed, solved, and post-processed in
the SimScale API to modeFRONTIER
the cloud.

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 Engineering Simulation in the Cloud

and VOLTA. All of this was possible while running 10 million simulations in order
accessing the practically unlimited power to analyze the whole parametric
and speed of the cloud. space. Using the Onshape-SimScale-
modeFrontier-VOLTA software stack, only
Internal Flow CFD: Among the available
65 of these permutations are required
CFD solvers, this project used the Finite
to be solved in order to get the optimal
Volume Method Cut-Cell to solve for the
result. All of the 65 permutations can be
internal flow. Users could analyze the
run in parallel using SimScale for further
pressure distribution within the pump
speed enhancement, which is an important
and understand its performance to find its
capability as you scale up the parametric
optimal design.
space to include more dimensions and

Massively Parametric Optimization: other variables such as material property

This specific CAD model has seven and load variations needed for Design

parameters. If we want to look at 10 values for Manufacture/tolerancing studies.

per parameter, then that would require

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Objective-driven Optimization

Bypassing the Classical Trial-and-error Approach

In the centrifugal pump use case discussed which takes a belt and braces approach
in this whitepaper, the engineers are faced to simply sweep and simulate the entire
with the challenge of optimizing their parametric space with no guarantee
pump design based on seven parametric of finding the optimal solution.
variables. The engineers leveraged The end-to-end design optimization
Multidisciplinary Design Optimization workflow is realized and scaled by
(MDO) available in modeFRONTIER. sharing data across the project team via
This optimization technology is game the VOLTA SPDM platform. In this use
changing for two reasons: The design case, the project team includes users of
update process is fully automated and the Onshape, SimScale, and modeFRONTIER.
optimization is driven by highly efficient In fact, VOLTA allows users to work in
algorithms capable of getting to the global a collaborative web-based platform where
optimum using a very limited number of CAD and CAE models can be shared
design iterations. This approach bypasses together taking advantage of automated
the classical trial-and-error approach, processes and optimization algorithms.

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 Objective-driven Optimization

Implementing the Optimization Feedback Loop

The first step was to create an automated algorithm is used to handle the search for
simulation process workflow using the optimal design. The simulation process
modeFRONTIER, integrating a Python workflow, together with the defined
script that leverages both the SimScale and optimization strategy are then uploaded to
Onshape APIs to modify the Onshape CAD the VOLTA platform to execute the runs in
model plus run the SimScale simulation a distributed environment. Optimization
with the updated geometry. The next step results are then post-processed in
is to set up a dedicated environment for the VOLTA Advisor, using advanced
the optimization strategy, which can be visualization tools to properly address the
accessed both from modeFRONTIER, optimized centrifugal pump design directly
via desktop, and VOLTA, via web, where in the browser. Results can be easily
the proprietary self-adaptive pilOPT shared with members of the project team.

Visualization of the seven input geometry parameters and the required output objective variables and other
results in the Application script node of modeFRONTIER Automation Workflow.

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 Objective-driven Optimization

In the image below, the scatter bubble plot highlights the efficiency of a candidate optimized
centrifugal pump, showing the corresponding result image and radar chart along with it.

VOLTA Advisor: Selection of optimal design solutions from the optimization scatter plot,
with details of the CFD field results and parameters’ values.

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Conclusions

This whitepaper illustrates the power and can maximize their engineering and IT
value of geometric parameterization of investments. Moreover, they can also
a simulation model coupled with design incorporate human task sequencing on top
optimization feedback. A fully integrated of the simulation workflows, ensuring that
and automated workflow is described the information reaches the right people at
and realized using Onshape and SimScale the right time, from single domain experts
APIs, linking Onshape, SimScale, and the to decision makers.
engineering tools offered by ESTECO.
Schedule your personalized live demo with
By adopting a modern cloud-native CAD SimScale today.
and simulation tool workflow together
Request a Demo
with process automation and decision
optimization stacks, organizations

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 Conclusions

W H I T E P A P E R

About Onshape About SimScale

Onshape is a next-generation SaaS SimScale provides SaaS engineering

design platform that speeds up product simulation in the cloud giving engineers
development. It’s an all-in-one system and designers immediate access to
that combines CAD, release management, digital prototyping early in the design
workflow, collaboration, analytics, admin stage, throughout the entire R&D and
tools, and an API with more than 50 product development cycles, and across
engineering applications. Onshape helps the entire enterprise. The SimScale
extended design teams work together platform enables engineering teams to
faster and helps executives make better innovate faster by making high-fidelity
business decisions with real-time analytics engineering simulation truly accessible
and unprecedented visibility into their from everywhere, and at any scale. Being
company’s design and manufacturing a cloud-native engineering simulation
processes. Onshape is a SaaS business platform, SimScale seamlessly integrates
unit of PTC. For more information, visit everything required for an end-to-end
onshape.com. simulation workflow, from design to
engineering, making broad and early use
of simulation for the first time technically
and economically accessible for any
organization. Simulation in SimScale is
performed through a single, collaborative
platform that delivers the accuracy
required for late-stage design validation
with the ease of use needed for early-stage
design simulation. You can request a 1:1
demo by visiting simscale.com.

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 Conclusions

About ESTECO

ESTECO is an independent software engineering experience, accelerating the

company, highly specialized in numerical decision-making process and reducing
optimization and simulation process development time. ESTECO is the owner
and data management. The company of VOLTA, the innovative enterprise
relies on a sound scientific foundation platform for Simulation Process and Data
and embraces a flexible approach to Management and design optimization,
meet customer needs. ESTECO offers and modeFRONTIER, the leading
innovative and flexible solutions to software solution for simulation process
safely create, capture and cultivate automation and optimization in the
engineering knowledge and address the engineering design process. To learn more
challenges of digital transformation. about ESTECO technologies or request
With more than 20 years of experience, a demo of modeFRONTIER and VOLTA,
ESTECO supports over 300 international visit engineering.esteco.com.
organizations in excelling in their digital

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