A CAE simulation is a digital process used to test and evaluate a product’s physical behavior under real-world conditions, without the need for a physical prototype. The most common simulation types include Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD). CAE is widely adopted across industries such as aerospace, automotive, consumer products, and energy to reduce costs, save development time, and improve product quality.
Benefits of CAE Simulations
CAE simulations offer a range of advantages that enhance the product development process. Here are just a few of their benefits.
- Time Savings – Accelerate development cycles by identifying design flaws and optimizing performance virtually, reducing the need for multiple physical prototypes.
- Cost Reduction – Reduce expenses by minimizing the reliance on physical testing and lowering material waste, all while improving efficiency across the product lifecycle.
- Improved Product Quality – Simulate and refine designs under a variety of real-world conditions, leading to higher-performing, more reliable products that better meet customer expectations.
How Does a CAE Simulation Work?
A typical CAE simulation has a series of steps that work together to inform engineering choices before any physical prototype is built.
- The process begins with pre-processing, where engineers develop a 3D model of the product and define the physical forces or environmental conditions it will face.
- During the analysis phase, the model is tested using specialized CAE software to simulate real-world behaviors.
- In post-processing, results are visualized and interpreted to evaluate product performance and determine the most optimal manufacturing method.
Applications
CAE is utilized across a wide range of industries. Some examples include:
- Aerospace
- Automotive
- Consumer products
- Marine
- Ship design
- Electronics
- Energy
- Construction
- Life sciences
- Turbomachinery
- Sports
The Most Common Simulation Types
CAE simulations can be divided into several sub-domains, each addressing a different aspect of product design.
Finite Element Analysis (FEA)
Finite Element Analysis is used to predict how a product will respond to real-world physical effects such as stress, heat, and vibration. It’s widely employed across industries where physical testing is impractical, allowing engineers to model many types of components with high precision, safety, and efficiency.
Computational Fluid Dynamics (CFD)
Computational Fluid Dynamics examines how fluids, liquids, and gases interact with surfaces and flow through systems. It enables engineers to simulate and study key variables such as pressure, temperature, velocity, and density, making it essential in a wide variety of industries.
Multibody Dynamics and Kinematics (MBD)
Multibody Dynamics simulates how the joints that connect the parts or components of a complex system work together. MBD helps predict how complex systems involving a large number of interconnected bodies or parts will behave and ensures their structural reliability.
Boundary Element Method (BEM)
The Boundary Element Method is commonly used for solving problems involving complex physical boundaries. BEM is highly effective for numerical simulation of contact problems.
Mechatronic System Simulation – 1D CAE
Mechatronic System Simulation focuses on modeling the performance of systems that combine hydraulic, electrical, pneumatic, and mechanical systems. It helps engineers determine the optimal integration of these systems to improve overall product functionality.
A Real Life Case Study
Divergent is transforming the automotive industry by rethinking how vehicles are designed and manufactured. By leveraging advanced tools like Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and other technologies, Divergent replaces conventional manufacturing processes with highly efficient, cost-effective, and sustainable methods. With over 500 patents in additive manufacturing and 3D printing, the company is leading innovation in vehicle design and manufacturing.
Introducing TotalCAE
To support its demanding simulation workflows, Divergent partnered with TotalCAE to overcome the limitations of on-premises workstations, which struggled to deliver the speed and scalability needed for high-volume CFD and FEA tasks.
In addition, Divergent also turned to TotalCAE for expert handling of their HPC environments and CAE application integration. TotalCAE delivered a fully managed hybrid HPC solution, enabling Divergent to reduce simulation turnaround times and focus on innovation.
As a result, Divergent achieved vehicles that are up to 70% lighter than those produced using traditional manufacturing techniques.
“TotalCAE makes it easy for Divergent to adopt the latest HPC solutions and CAE application versions to benefit our engineers, freeing up my team to focus on other IT missions. TotalCAE has been a great partner in keeping our CAE team happy and working productively.” – John Lucas, Director of IT at Divergent
Learn more about this and other use cases by visiting our HPC Success Stories page.
Harness the Power of HPC & CAE With TotalCAE
At TotalCAE, we specialize in delivering fully managed high-performance computing (HPC) solutions, including on-premises, cloud, and hybrid HPC solutions, to accelerate your CAE simulation workflows. Companies across industries like automotive manufacturing trust us to enhance simulation speed and eliminate IT complexity.
Contact us today to learn how our HPC solutions can help you achieve faster, more efficient engineering outcomes.
Frequently Asked Questions
Learn more about CAE simulations.
What Is The Difference Between CAE, FEA & CFD?
The difference is that Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) are subdomains of CAE, each serving a specific purpose. Together, these tools help engineers evaluate and optimize product designs quickly, while saving significant costs.
What Is The Difference Between CAD & CAE?
Computer-Aided Design (CAD) is used to visualize a product idea or design, while Computer-Aided Engineering (CAE) focuses on analyzing and simulating how that design will perform under real-world conditions.
Who Uses CAE?
CAE is widely used across nearly all major industries, from automotive and aerospace to healthcare. Engineers and designers rely on CAE software to simulate, test, and refine product designs, ensuring performance, safety, and efficiency without the need for costly physical prototypes.