Design simulations and analyses
To thoroughly analyse and map out a process or design problem, we use advanced simulations, analyses and calculations. This is one of our specialities, which we use to solve a wide range of engineering challenges.
By simulation, we mean accurately representing physical reality in a digital environment. During an analysis, we break down and examine a complex problem into its individual parts.
With a targeted simulation, we improve the quality of the product or machine while simultaneously reducing costs. Simulations give us in-depth insight into how a product or assembly of components behaves under specific conditions. Based on these results, our specialists can make better technical and functional decisions, and go on to predict and improve product performance, functionality and reliability.
The benefits of early simulation within a project:
Cost reduction: Effectively reducing the final production costs.
Risk minimisation: Minimising the chance of critical design errors.
Faster workflow: Speeding up the workflow of the entire project, saving time and money worldwide.
Problem prevention: The earlier the simulation can be carried out, the better. This significantly reduces the chance of problems arising later on.
FEM Analysis (Finite Element Method)
An FEM analysis (Finite Element Method) is, at its core, an advanced strength calculation. It allows us to accurately predict how a product, machine component or assembly of components behaves under the influence of forces or external factors. Rather than moving straight to prototyping, we use specialist simulation software to test in advance whether a design meets all the specified requirements.
It is advisable to calculate how machine components will behave early in the development process. This allows us to catch problems at an early stage and gives us the opportunity to optimise the design in good time. A thorough FEM analysis prevents unnecessary physical testing and substantial loss of time.
CFD Analysis (Computational Fluid Dynamics)
To accurately simulate gas and fluid flows, High Tech Alliance carries out a CFD analysis. CFD stands for Computational Fluid Dynamics. This method is extremely well suited to visually mapping gas and fluid flows through computer simulation and making their effect on the system visible.
Thermal analyses for complex heating and cooling processes are also possible. This makes a CFD analysis an attractive tool to deploy early in the design process. By accurately assessing performance in a virtual environment, you avoid a costly and time-consuming trial-and-error process in practice.
Design optimisation
Based on an initial simulation, we make a targeted assessment of where gains can be made for your system. High Tech Alliance has extensive experience in complete design optimisation using simulation techniques such as FEM and CFD. We provide the right support to optimise the machine or product design for our international clients down to the smallest detail.
The possibilities for your product or machine
Improve the quality of your product or machine and minimise risks and costs with professional simulations and analyses. Curious how we can virtually validate your technical projects? Please feel free to contact us for more information or a focused consultation.
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FEM Analysis: Advanced Strength Calculations for Product Development and Machine Building
An FEM analysis (Finite Element Method) is a high-quality method for performing complex strength calculations during the design phase of a new, innovative product, device or machine. When a standard analytical calculation is not possible due to high complexity, this simulation technique offers a solution.
High Tech Alliance's engineers use FEM analyses to underpin critical decisions. This includes selecting the most suitable material, checking whether a structure is strong enough to withstand varying loads, and ensuring that the design strictly complies with all applicable strength requirements.
How simulations work and their strategic benefits
Using powerful software, our specialist engineers make accurate, virtual predictions of reality. Mechanisms, components and complete machine assemblies are precisely assessed for deformation, strength, stiffness and material fatigue. Detailed 3D visualisations reveal, at an early stage, where structures will bend or twist and how critical stresses develop.
This process offers major economic and technical benefits for a wide range of industrial sectors worldwide:
Shorter Time-to-Market: Physical test setups and prototypes are kept to a minimum.
Cost reduction: Early optimisation reduces production, assembly and operational costs alike.
Risk management: Sources of failure and technical risks with potentially major financial consequences are eliminated in advance.
Standards compliance: The concept is quickly and efficiently tested against international standards, guidelines and regulations.
Note: Because incorrect boundary conditions or material choices can quickly introduce errors into a simulation, this method requires a great deal of expertise. High Tech Alliance's experienced engineers have mastered this speciality down to the smallest detail, keeping risks to an absolute minimum.
Different Types of FEM Analysis and Applications
Depending on the specific mechanical issue, we carry out various types of analysis within sectors such as machine building, aerospace, automotive, civil engineering, shipbuilding and the medical industry:
Static FEM analysis: Focuses on stationary (non-moving) components such as machine frames and steel structures.
Linear: There is a constant relationship between forces and displacements (stiffness remains constant), ideal for a quick initial estimate.
Non-linear: Applied to complex problems involving large geometric or plastic material deformations, where stiffness varies under load.
Dynamic FEM analysis: Analyses the behaviour of mechanisms and drive systems subject to variable or shock loads over time, taking explicit account of mass-inertia effects and structural degradation.
Natural Frequency FEM Analysis (Modal Analysis): Determines the natural vibration frequencies and corresponding deformations of a structure. This is essential to prevent peak loads and harmful resonance – for example caused by an external drive – and to guarantee a long service life.
Need help with FEM analyses?
Curious how an expert FEM analysis can guarantee the reliability and quality of your new machine or equipment? Feel free to contact High Tech Alliance for a focused consultation.
Do you have a technical challenge?
And are you looking for a partner for in-depth engineering knowledge, project management, or specific expertise? Then please contact us to jointly explore the possibilities.