MegaSim: Test Your Design Before You Build It
Identify design flaws, optimize performance, and drastically reduce the need for costly physical prototypes. Our "MegaSim" engineering simulation services use advanced Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) to give you the data you need to build a better product from the start.
- Slash Prototyping Costs: Validate your design virtually, significantly reducing the number of expensive physical prototypes and test cycles.
- Optimize Product Performance: Simulate real-world conditions to analyze stress, thermal performance, and fluid dynamics, allowing you to optimize your design for maximum reliability.
- Solve Problems Before They Happen: Discover potential failure points, stress concentrations, and thermal issues at the earliest stages of design, when fixes are easiest and cheapest.
- Partner with Simulation Experts: Leverage our team of expert engineers to translate complex simulation data into practical, actionable design improvements.
*Tell us about your project for a detailed quote and analysis plan. No obligations.
Trusted by Industry Leaders and Innovators
The team was easy to communicate with, quick to respond, and truly committed to our success. Marty, Vic , Soliman, and even the accounting team provided us with white glove service. Not to mention that their facility is truly impressive!
We wouldn’t hesitate to work with them again, in fact we are looking forward to it!
The Challenge: Physical Prototypes are Slow and Expensive
In traditional product development, each design iteration requires building and breaking a physical prototype. This cycle is incredibly slow, expensive, and often reveals critical flaws far too late in the process, leading to major redesigns and launch delays. To compete in today’s market, you need a faster, smarter, and more cost-effective way to validate your design.
Our Suite of "MegaSim" Engineering Simulation Services
We provide a holistic approach to virtual testing, allowing you to see how your product will behave in the real world before a single part is manufactured.
- Finite Element Analysis (FEA): We use FEA to simulate the physical forces on your product. This includes Structural & Stress Analysis to find weak points, Vibration Analysis to understand resonant frequencies, and Fatigue Analysis to predict your product’s service life.
- Computational Fluid Dynamics (CFD): For products that interact with liquids or gases, our CFD analysis is essential. We simulate fluid flow to optimize aerodynamics, analyze pressure drops, and ensure effective thermal management through airflow.
- Thermal Analysis: Heat is a primary cause of electronic failure. We simulate the thermal performance of your components and enclosures, identifying hot spots and ensuring your cooling strategies are effective before you build a thermal prototype.
Our Simulation Expertise in Action
Here are a few examples of how we've helped clients solve complex design challenges, reduce costs, and accelerate their time-to-market using our MegaSim platform.
Problem: DHP Company needed to verify the structural integrity of a complex heat exchanger system and get a high-quality estimation of its fatigue life under various operational loads and temperatures.
Solution: We performed a detailed Finite Element Analysis (FEA) on the entire assembly, simulating the complex interactions between all components to analyze structural stress under thermal and operational loads.
Result: The simulation provided DHP Company with the actionable data needed to validate the system’s structural integrity and provide a reliable fatigue estimation for their design verification.
Problem: The client needed to analyze the complex dynamics of an entire amusement park ride mechanism, considering factors like schatter in the loading.
Solution: We performed a multibody dynamics analysis combined with a stress analysis to create a comprehensive life and compliance study of the ride’s structure and mechanisms.
Result: The simulation provided a detailed understanding of the ride’s dynamic behavior and structural stress, delivering the data required for the client’s life and compliance validation.
Problem: The client needed to analyze the stress and deformation of a very large distillation tower (30m high, 3m diameter) made of SA 516 Gr 70 steel under an internal pressure of 5.86 MPa.
Solution: We performed a detailed stress and deformation analysis on the large-scale model, simulating the effects of the specified internal pressure on the entire structure.
Result: The analysis provided a clear understanding of the stress and deformation patterns, validating the structural integrity of the distillation tower design under its operational pressure.
Problem: The client needed to understand the structural performance of a specific plate-and-screw repair technique (Champy technique) for a fractured mandible.
Solution: We conducted a highly complex simulation involving nonlinear pull-out analysis, bio-material characterization, and advanced modeling techniques to assess the repair’s structural integrity.
Result: The simulation provided a detailed analysis of the structural performance of the repair, delivering valuable data for the client’s biomechanical research and design validation.
Problem: The client needed to analyze the vibration and stiffness performance of an aluminum carbody wagon to meet specific NVH (Noise, Vibration, and Harshness), ride, and comfort requirements, with a goal of 95% correlation with physical test results.
Solution: We conducted a detailed design and analysis of the aluminum carbody, simulating its vibration and stiffness performance to optimize for the client’s NVH and comfort targets.
Result: The simulation successfully modeled the wagon’s performance with a high degree of accuracy, providing the client with the data needed to meet their challenging 95% correlation target and fulfill their design requirements.
Problem: The client needed to understand the thermal performance of a large, air-cooled Lithium-ion battery pack without conducting a full transient simulation, and they required a high degree of accuracy.
Solution: We performed a computational fluid dynamic (CFD) and thermal analysis of the battery pack, including a thorough uncertainty analysis to prove the accuracy of the measurements.
Result: The simulation accurately modeled the thermal performance of the air-cooled battery pack, and the uncertainty analysis provided the client with high confidence in the accuracy of the results.
Problem: A client needed to establish safe operating conditions and design limits for hydrogen storage cylinders that would be subjected to fire and thermal shock.
Solution: We developed a detailed combustion model to simulate the thermal and mechanical loads on the cylinders during a fire, analyzing the lamina stacking sequence and thickness.
Result: The thermal analysis provided the client with clear design limits and validated the safe working conditions for the hydrogen storage cylinders, ensuring their integrity under extreme thermal events.
Problem: The client needed to verify the structural integrity of both a vessel and its mounting system during and after a crash, drop, or vibration event.
Solution: We developed a complex simulation using advanced fracture mechanics, material modeling, and careful calibration to accurately model the crash and post-crash behavior of the entire system.
Result: The simulation successfully validated the structural integrity of the vessel and its mounting system, providing the client with the data needed to confirm the design’s safety and resilience.
Problem: The client needed to verify the structural integrity of both a vessel and its mounting system during and after a crash, drop, or vibration event.
Solution: We developed a complex simulation using advanced fracture mechanics, material modeling, and careful calibration to accurately model the crash and post-crash behavior of the entire system.
Result: The simulation successfully validated the structural integrity of the vessel and its mounting system, providing the client with the data needed to confirm the design’s safety and resilience.
