Next dimension in development process
Analysis of early stage prototype design or improvement of an existing product or production process can be effectively done using virtual product development. This contemporary interdisciplinary approach combining design optimization techniques and finite element analysis is an alternative to classical way of product design which is based on time- and cost-unfavourable testing and expensive trial-and-error processes.
Virtual prototypes cost less to produce and design changes are easier to make then empirical upgrades and modifications of physical prototypes. Nevertheless we realize the significance of physical testing for virtual simulation. Material tests are essential as a source of data for advanced constitutive laws. Full-scale physical test are needed for validation and calibration of complex computational models.
Typical Optimization Process
Benefits
Typical benefits of the virtual product development and optimization:
- Shorten the time-to-market
- Reduced development costs
- Fast evaluation of problems in early stage of design
- Replace experimental trial-and-error processes
- Improved product performance at defined level of reliability and serviceability
- Reduced production cost
Our consultancy team possesses extensive experience and know-how in setting up advanced parametric FE-models, FE-analysis and evaluation of structures performance and latest design optimization techniques.
Simulation and Optimization Techniques
We offer our customers simulation and optimization techniques, which can be integrated into their current-state product development process:
- Parametric Modeling
- Virtual Prototyping
- Topological Optimization
- Sensitivity Analysis (shows how the uncertainty in the output of a FE-model can be apportioned to different sources of uncertainty in its inputs)
- Design Space Exploration
- Verification and Validation of Computational Model
- Multi-objective Optimization (reduction of production costs and improvement of performance and reliability, often reduction of production costs while achieving target performance)
- Parametric Tolerance Analysis of Mechanical Assemblies
- Model Calibration and Inverse Parameter Identification
Frequently asked questions
These are the questions engineers and development leads ask most often before starting a virtual product development or optimisation project: whether simulation can replace physical testing in their case, what you need to define upfront, and what a finished optimisation actually delivers. Answered directly, without sales language.
What is virtual product development and why is it better than physical prototypes?
What we do:
- Build computational models to test different design variants
- Identify weaknesses and propose modifications before manufacturing
- Combine simulations with optimisations — topology optimisation, parametric studies, multi-objective optimisation
Benefit for your project:
- Fewer prototypes, faster development, lower iteration costs
- Design changes in simulation take hours — on a physical prototype take weeks.
- Without simulation you resolve every variant with a prototype; with simulation you only validate an already-verified design.
- If development proceeds without a simulation phase, the cost of fixing errors grows with each project phase — the later the detection, the higher the price.
When to act:
- As early as possible — ideally in the concept or early design phase, where there is the most room for genuine improvement. This is the standard approach for projects where decisions affect production, costs, or safety.
What can you optimise?
Weight, stiffness, strength, fatigue life, or manufacturing cost — depending on what is the priority for your project.
What we do:
- Topology optimisation — where material actually carries load and where it is redundant
- Parametric studies and sensitivity analyses — how structural behaviour changes with key parameter variations
- Multi-objective optimisation — finding a compromise between multiple goals simultaneously, e.g. weight versus service life
Your result:
- A specific design with verified performance — on this basis you decide which variant goes to production
Can you connect the virtual model to real-world operations?
Yes — we have this verified on a real project. We contributed to the development of the digital twin of the Bystřička dam — a system that monitors the state of the hydraulic structure in real time, simulates operational scenarios, and predicts structural behaviour before anything happens. The project was recognised among best practices by the European Cluster Alliance.
What this means for your projects:
- A virtual model doesn’t have to be a one-off tool — it can become a permanent part of operations and decision-making processes
- Connecting FEA simulations with real operational data opens up possibilities for predictive analysis and continuous monitoring
What this means for you:
- Read more about digital twins in the Digital Twins section
Can you automate optimisation processes and connect them to our workflow?
Yes — this combination is what differentiates DESIGNTEC from purely consultancy firms.
What we do:
- Our team includes both FEA experts and software developers
- We can automate optimisation loops and connect them to your environment — ANSYS Workbench, DesignXplorer, custom pipeline
- We develop custom tools that handle repeated analyses without manual intervention
Benefit for your project:
More on automation options you can find in the ANSYS Customization and Automation section.
Without automation you re-solve the same type of optimisation from scratch each time.
With automation you do it once — and the return on investment is apparent after the first few repetitions.
Do you work on machine learning systems?
Yes. We are currently developing a next-generation version of the Bystřička dam digital twin platform using machine learning and reduced-order models. The goal is a significantly faster and less computationally intensive alternative to full FEM models — suitable for operational decision-making, not just retrospective analysis.
What this means for your projects:
- Combining physics-based simulations and ML models enables real-time predictive analysis — not just retrospective assessment
- This area represents active R&D for us, not a distant prospect
What this means for you:
- More about our research activities you can find in the R&D Projects section
Have a specific case? Send us an example — we’ll assess it and give you a specific process proposal. If it doesn’t make sense, we’ll tell you that too.
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