Exploring barriers for the use of FEA-based variation simulation in industrial development practice

Abstract Over the last decades, finite element analysis (FEA) has become a standard tool in industrial product development, allowing for virtual of designs, quick turnaround times and prompt implementation results. Although academic research also provides numerous approaches evaluating product’s robustness towards geometrical, material load variations based on FEA analyses, this, however, stands striking contrast to limited use these FEA-based variation simulations industry. In order bridge existing gap between application, this paper explores barriers that limit adoption simulation. The investigation is interviews with five lead engineers, followed by case study details underlying technical challenges allows some initial suggestions future solutions. involves sterile canister seven geometrical variables. design objective ensure sufficient sealing within range expected probabilistic variation. combined identified main wider is, lack robust CAD, practical guidelines select an efficient experiments purposes, complexity automated processes. From perspective, results estimations interaction effects, accurate metamodel Monte Carlo 100,000 samples providing engineer more detailed actionable insights performance compared traditional nominal or best/worst simulations.