FEA and simulation with documented assumptions
Analysis results you can defend in design review. We document boundary conditions, verify mesh convergence, and deliver reports that explain not just what the numbers are, but what they mean for your design.
Request engineering supportProblems we solve
Simulation is only valuable if people trust the results. We see teams struggle when analysis exists but no one can explain the assumptions behind it.
What you receive
Every analysis produces documented outputs your team can review, question, and build upon.
Analysis reports
Complete documentation of methodology, assumptions, results, and recommendations in a format ready for design review
Mesh convergence studies
Verification that results are independent of mesh density, with documented refinement progression
Boundary condition documentation
Clear rationale for loads, constraints, and contacts with traceability to requirements or test data
Factor of safety summaries
Stress margins and safety factors calculated against material allowables with clear pass/fail criteria
Sensitivity analyses
Parametric studies showing how results change with input variations
Model files and setup notes
Native simulation files with documented settings so analyses can be reproduced or extended
Our approach
A structured process that produces defensible results, not just colorful stress plots.
Define scope
We clarify what questions the analysis needs to answer, what loads and conditions apply, and what success criteria look like. This prevents scope creep and wasted cycles.
Model setup
Geometry prep, mesh generation, material assignment, and boundary condition application. We document every choice and its rationale.
Analysis
Run the solver, verify convergence, check for errors or warnings, and extract results. Multiple load cases or parametric sweeps as needed.
Report
Deliver a structured report with methodology, assumptions, results summary, and actionable recommendations. Review-ready, not just raw output.
Tools we use
We work with industry-standard simulation software. If you have existing models in these platforms, we can pick up where you left off.
ANSYS Mechanical
FEA
SolidWorks Simulation
FEA
ABAQUS
FEA
ANSYS Fluent
CFD
SolidWorks Flow Simulation
CFD
SolidWorks Motion
Motion
Analysis types
We handle a range of physics and loading conditions. Most projects combine multiple analysis types.
Static structural
Stress, strain, and displacement under static loads
Thermal
Steady-state and transient heat transfer
Fatigue
Cycle life prediction and damage accumulation
Modal
Natural frequencies and mode shapes
Harmonic response
Response to oscillating loads
Motion & dynamics
Mechanism kinematics and reaction forces
Nonlinear
Large deformation, contact, and plasticity
Buckling
Stability and critical load determination
Representative engagements
Examples of how we've helped teams solve simulation challenges. Details anonymized to protect client confidentiality.
Thermal management for high-power electronics enclosure
Industrial automationChallenge
A controls manufacturer needed to verify that a new power electronics enclosure would stay within thermal limits under peak load conditions. Previous analysis had shown acceptable temperatures, but the assumptions were undocumented.
What we did
We rebuilt the thermal model with documented boundary conditions based on component datasheets and test data. Ran steady-state and transient analyses for multiple operating scenarios. Identified a hotspot near the power stage and recommended vent repositioning.
Outcome
Updated enclosure design passed thermal qualification testing on the first attempt. Analysis report became the reference document for future variants.
Fatigue life assessment for suspension component
AutomotiveChallenge
An automotive supplier received field returns of a suspension bracket with fatigue cracks. They needed to understand the root cause and validate a proposed redesign before committing to new tooling.
What we did
Performed static and fatigue analysis on both original and proposed designs. Documented load cases from customer duty cycle data. Mesh convergence study showed the original analysis had used insufficient refinement at fillet radii.
Outcome
Identified stress concentration 40% higher than original analysis indicated. Redesign with increased fillet radius showed 3x improvement in predicted fatigue life. No field failures reported after production change.
Common questions
What information do you need to start an analysis?
At minimum, we need CAD geometry (STEP or native format), material specifications, load cases with magnitudes and directions, and constraint conditions. Test data or field measurements for validation are helpful but not required.
How long does a typical analysis take?
A straightforward static stress analysis with one or two load cases typically takes 1-2 weeks including documentation. More complex analyses (thermal, fatigue, nonlinear) or multiple design iterations take longer. We provide timeline estimates before starting.
Can you work with our existing simulation models?
Yes. We can review, update, or extend existing models in ANSYS, SolidWorks Simulation, or ABAQUS. We document what we find and any changes we make.
What if the analysis shows the design fails?
We report what we find. If results indicate a problem, we include recommendations for design modifications and can iterate on the analysis as you make changes. Better to find issues in simulation than in production.
Do you validate simulation results against test data?
When test data is available, we correlate simulation predictions with measurements. This builds confidence in the model and helps calibrate boundary conditions for future analyses.
Need analysis support?
Tell us about your simulation challenge. We'll scope the work and provide a clear path forward.
Request engineering support