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Using Simulation in Product Design: 3 Success Stories

Andreea Zaharia
BlogAbout SimScaleUsing Simulation in Product Design: 3 Success Stories

simscale engineering simulation customer success stories and case studies


The reason why SimScale was created was to help engineers, designers, and manufacturers develop their better products better, faster, and cheaper with the help of engineering simulation (CAE software).

More than four years have passed since the initial release and many things have changed. And, while our mission stayed the same, the number of users has increased to over 80,000, plenty of simulation features have been added to the platform, and the SimScale Community was created.

The main reason why many our users choose the Professional or Enterprise account instead of the free Community plan is that they want to protect their copyright and perform private simulations for their product design. This is common for the majority of our users who are working on a new product, and there are a wide variety of products that can be simulated with SimScale, from electronics design to vehicles or AEC projects. (Take a look at this page for an application overview).

Three Success Stories

With this article, we would like to introduce a few of our customers and give you more information regarding products you can virtually test and analyze with SimScale. Here are three of our customer’s products tested and optimized on the SimScale platform:

1. Carlsson Autotechnik: Car Aerodynamics Optimization

Carlsson Autotechnik: Car Aerodynamics Optimization with SimScale

The design and development of sports cars and their components require proper testing and high-end tools to ensure product quality and performance.

Large automobile companies usually maintain several development departments with hardware, machines, and supercomputers for testing. Carlsson Autotechnik was facing the challenge of managing the same tasks while getting accurate results with limited resources.

Using SimScale’s pay-as-you-go model, Carlsson’s team was able to perform the Computational Fluid Dynamics simulations they needed, paying only for what they used and avoiding unnecessary expenses. With the simulation results obtained with SimScale, it was possible to examine and optimize the aerodynamics of their vehicle.

2. Tokyowheel: Simulating Premium Racing Wheels

Tokyowheel: Simulating Premium carbon fiber bike Racing Wheels design with SimScale

Founded in 2010 and based in Japan, Tokyowheel is a highly-specialized company that is designing and manufacturing technical carbon fiber racing wheels for competitive cyclists. Their carbon wheels used for the road, triathlon, and cyclocross bikes provide significant performance improvements through decreased aerodynamic drag of the wheel shape and the decreased mass of the lightweight carbon fiber construction.

Contemporary aerodynamic wheels require the use of Computer-Aided Engineering (as opposed to historical methods of prototyping and wind tunnel testing). While historical methods certainly produced competitive results and moved the industry forward, they were time-consuming and required significant resources. CAE provides similar results in much less time, and with a significantly smaller investment.

Computational Fluid Dynamics is prohibitively expensive, with annual subscriptions usually costing tens of thousands of dollars. Looking to work around these wasteful expenses, the SimScale platform was what the engineers at Tokyowheel were looking for.

SimScale enabled them to perform fluid flow simulations of a variety of strategically different wheel designs in a timely manner. A traditional local computer-based system would have severely limited the number of design experiments that could have been run in the same amount of time.

By using SimScale’s cloud-based platform, Tokyowheel’s team ran several simulations, and in turn, iterated many more design changes. Each design change was quickly implemented in CAD and tested in the SimScale environment, making changes based on the simulation results and ultimately creating better products.

3. Malaika: Designing Safer Car Seats for Children

Malaika car seat design fea simulation

Adopting a blank canvas approach and using engineering and design methods from the aviation industry, the Malaika team is promising a child car seat that is significantly safer, lighter, and easier to use.

They are designing the world’s first range of child car seats that will surpass every international safety standard, effectively raising the bar for child safety. To meet such a challenge, the engineers at Malaika have implemented rigorous product testing and design verification procedures at all levels of production.

The SimScale platform has been a part of this intricate process. And a series of component simulations validated the structural integrity of the primary Isofix connection to the main chassis and the adjustment rack. Finite element simulations were conducted with the SimScale cloud-based platform based on worst case scenarios.

There are many more products simulated with SimScale every day. Browse the Public Projects for an overview. And remember: all you must do to keep your products private is upgrade to the Professional Plan.

Discover all the simulation features provided by SimScale. Download the document below.


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