Solutions & Applications
Engineering Simulation Solutions by Industry and Application
From launch vehicles and orthopedic implants to EV battery packs and substations, see how engineering teams use Altair and Siemens simulation to solve the problems specific to their industry, and find the right tools for yours.
Explore Our Solutions
Simulation Solutions for Every Engineering Industry
Tailored workflows for the unique challenges of each industry, from simulation and design to manufacturing and data-driven engineering. Pick yours, or let the Solution Finder match your problem to a tool.
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Structural Simulation
Structural Simulation for Stress, Vibration and Durability
Structural simulation predicts how parts and assemblies respond to real loads before anything is built: stress hot spots, excessive deflection, buckling risk, vibration and fatigue life. It is the most widely used form of finite element analysis in product development.
The right fidelity depends on the decision. Meshless SimSolid answers design questions on full CAD assemblies in minutes; OptiStruct and Simcenter 3D handle linear and nonlinear analysis with contact, plasticity and optimization; Radioss covers crash and impact. We help teams choose the level, build repeatable workflows and train users so structural analysis becomes a routine engineering decision, not a one-off study.
- Linear and Nonlinear Static
- Modal, NVH and Random Vibration
- Fatigue and Durability
- Buckling and Stability
- Crash, Drop and Impact
- Topology and Size Optimization
SimSolid · Full AssemblyChoosing the Right Structural Simulation Tool
Tutorials from our engineers: SimSolid connection tolerances, shrink wrap meshing for dirty CAD and PhysicsAI step by step.
Aerospace & Defense
Aerospace and Defense Simulation
Aircraft, UAV and space programs live on margins of weight, heat and signal. Simulation lets teams prove aerodynamics, structures, avionics cooling and RF performance before hardware and qualification testing.
Challenges We Solve
- Lift, Drag and Stability Across Aircraft, UAVs and Space Vehicles
- Lightweight Composite Structures That Still Meet Fatigue and Safety Targets
- Antenna Placement, Radomes and EMC/EMI on the Installed Platform
- Avionics Thermal Management in Extreme Environments
- Shock and Random Vibration for Electronics and Shipboard Equipment
- Digital Thread and Configuration Control Across the Program
Recommended Tools
Drones & UAV
Drone and UAV Design Simulation
Endurance depends on weight, drag, structural efficiency, thermal behavior and propulsion together. Simulation finds the grams, the drag and the interference risks before the next prototype flies.
Simulation-Driven Drone Development
Drone programs combine CAD, structural simulation, aerodynamics, electromagnetics and controls. Inspire and OptiStruct lightweight the airframe, SimSolid checks changing assemblies fast, FlightStream and STAR-CCM+ resolve aerodynamics and cooling, Feko protects control links and telemetry, and PSIM with Embed develops propulsion and flight-control code. Siemens NX and Teamcenter keep the digital thread connected as the program scales.
- Fewer Build-Test-Redesign Loops While Layouts and Payloads Change
- Longer Endurance From Lower Mass, Drag and Electrical Losses
- Earlier Detection of Antenna Placement and EMC Risks
- Validated Motor-Drive and Control Strategies Before Flight Test
Customer proof: Kappa Electronics used Altair Embed to develop motor control for a new drone propulsion design.
Automotive & EV
Automotive and EV Engineering
Vehicle programs balance lightweighting, crash safety, NVH, aerodynamics, cooling and electrification at once. Connected Altair and Siemens workflows let teams iterate on body, chassis and e-drive designs before tooling.
Challenges We Solve
- Body-in-White and Chassis Mass Targets Without Losing Stiffness
- Crashworthiness and Battery Protection in Electrified Vehicles
- Aerodynamics, Cabin Comfort and Thermal Management
- E-Motor, Inverter and Battery Interaction With Controls
- Antenna Performance and EMC for Connected Vehicles
- Traceability Across Design, Simulation and Manufacturing
Medical Devices
Medical Device Engineering Solutions
Implants, wearables and diagnostic systems must be safe, reliable and documented. Simulation supplies verification evidence for structural, thermal, fluid and electromagnetic behavior while cutting physical test iterations.
Challenges We Solve
- Implant Stress, Fatigue and Long-Term Durability Under Physiological Loads
- Heat Dissipation in Handheld, Wearable and Diagnostic Devices
- EMC/EMI, Antennas and Wireless Links in Connected Devices
- Sensors, Actuators and Control Logic in Electromechanical Systems
- Molded Plastic Parts and 3D-Printed Lattice Structures
- Design Verification and Traceability for Regulated Development
Electronics & RF
Electronics and Electromagnetic Simulation
From phased arrays and 5G antennas to motor drives and dense PCBs, electronics teams use simulation to catch signal, power, thermal and EMC problems before boards are spun and enclosures are tooled.
Challenges We Solve
- Antenna Design, Installed Performance and Coverage
- EMC/EMI Compliance Before Chamber Testing
- Converter, Inverter and Motor-Drive Efficiency and Control Stability
- PCB Design Review, Signal Integrity and Manufacturability
- Electronics Cooling Inside Compact Enclosures
- Embedded Control Code That Matches the Simulated Design
Industrial Machinery
Industrial Machinery and Equipment Simulation
Heavy equipment, production machinery, robotics and bulk-handling systems face loads, wear and particle flow that are hard to test at full scale. Simulation optimizes them before steel is cut.
Challenges We Solve
- Strength and Deflection of Large Welded and Bolted Assemblies
- Bulk Material Flow, Wear and Segregation in Chutes, Hoppers and Buckets
- Mechanism Motion, Actuator Loads and Robot Dynamics
- Casting, Forming and Machining Quality for Production Parts
- Composite and Lightweight Structures for Moving Equipment
- Design Changes That Stay Synchronized With Manufacturing
Robotics & Autonomous Systems
Robotics and Automation Simulation
Industrial arms, mobile robots and AGVs, inspection drones and defense robotics all depend on mechanisms, motors, sensors and controls working together. Multibody dynamics sizes actuators and joints, topology optimization and additive manufacturing lighten links, Flux designs joint motors, CFD keeps electronics cool, and system models with digital twins validate the complete robot before it is built.
Energy & Utilities
Energy, Utility and Power Systems Simulation
Wind structures, generators, transformers, converters and storage all combine structural, electromagnetic, thermal and control physics. Simulation de-risks them before installation in the field.
Challenges We Solve
- Towers, Foundations and Floating Wind Structures Under Extreme Loads
- Generator, Transformer and Motor Efficiency and Losses
- Grid-Tied Inverters, Microgrids and Power Supplies
- Battery Thermal Management, Safety and Controls
- Asset Monitoring and Predictive Maintenance From Operational Data
Batteries & E-Mobility
Battery Engineering and Simulation
Battery programs rarely depend on one tool. Thermal behavior, structural protection, electrical losses, charging and BMS controls interact across cells, modules and packs.
Start with the dominant risk. SimLab, Altair CFD and STAR-CCM+ resolve cooling paths and hotspots; HyperMesh, OptiStruct and Radioss handle trays, enclosures and crash protection; PSIM and Flux model chargers, converters and busbars; Twin Activate and Embed connect BMS logic; Teamcenter keeps requirements and revisions traceable. Read Battery Simulation 101 for a full walkthrough.
- Thermal and Cooling Design
- Safety and Abuse Protection
- Pack and Tray Structures
- Charging and Power Electronics
- Controls and BMS
- Program Traceability
EV Pack · Modules
STAR-CCM+ · Electro-ThermalMultiphysics & CFD
Multiphysics Simulation and CFD
Real products don’t respect physics boundaries. Motors heat up, cooling flow loads structures, and electromagnetic losses drive thermal limits. Multiphysics simulation solves those interactions together for more accurate behavior.
Simcenter STAR-CCM+ couples flow, heat transfer, structures and electrochemistry in one environment; SimLab builds CAD-associated multiphysics models; FloEFD brings CFD into the designer’s CAD; and PhysicsAI learns from past runs to predict results in seconds. See PhysicsAI in STAR-CCM+ and our FEA vs CFD guide.
Electromagnetics
Electromagnetic Simulation Software
Electromagnetic simulation predicts electric and magnetic field behavior, including radiation, coupling, induction and saturation, before hardware exists. It is a different discipline from circuit-level electronics simulation, and most products need both.
High Frequency
Antennas, EMC and Radar With Feko
Antenna design and placement, installed performance, EMC/EMI, radar cross section and propagation when waves interact with complex structures.
Feko Details
Low Frequency
Motors and Devices With Flux
Motors, generators, coils, actuators and sensors, including magnetic saturation, losses and duty cycles in steady-state or transient analysis.
Flux Details
Circuits & Systems
Power Electronics With PSIM
Converters, inverters and motor drives at the circuit and system level, with SmartCtrl for control loops and Embed for code generation.
PSIM DetailsSee parametric antenna work in Simcenter Feko for World Cup stadiums and circuit optimization in HyperStudy and PSIM.
Manufacturing
Manufacturing Process Simulation
A part can pass structural FEA and still fail in production. Process simulation predicts how it will be cast, molded, formed, printed or machined, so defects, scrap and tooling rework are resolved before production.
Manufacturing Services
- Inspire CastAir entrapment, shrinkage porosity and cold shuts
- Inspire MoldFilling, packing, cooling, warpage and sink marks
- Inspire FormStamping formability, thinning and tearing
- Inspire ExtrudeMetal and polymer profile extrusion and die design
- Inspire PolyFoamPolyurethane foam filling, foaming and curing
- Inspire Print3DAdditive distortion, overheating and supports
- EDEMPowders, grains, ores and tablets in process equipment
- NX CAM2.5- to multi-axis toolpaths, collision checks and verification
Manufacturing analysis focuses on how a product is produced; structural FEA focuses on how it performs. Used together they close the gap between design intent and production reality. See porosity-constrained optimization in Inspire 2026.1.
Systems, Data & PLM
System Simulation, Digital Twins and Engineering Data
A product can work mechanically and still fail through controls, electronics or operations. System models, digital twins and analytics connect those behaviors to real-world data.
Twin Activate and Compose model multi-domain systems and automate analysis; RapidMiner, Panopticon, Monarch and Knowledge Studio turn operational and IoT data into predictive maintenance and real-time monitoring; Teamcenter carries requirements, BOMs and simulation results through the digital thread.
Panopticon · Live Data
Solution Finder
Not Sure Which Tool Fits Your Problem?
Answer a few questions about your physics, industry and workflow, and the Solution Finder matches you to the right Altair and Siemens technologies out of 39.
Expert Support
Expert Support for Your Industry Challenges
Work with experienced engineers who understand your industry and your technical needs. From first evaluation to advanced optimization, we collaborate closely with your team for successful adoption and measurable results.
Map Your Challenge
We review your products, physics, CAD environment and constraints to find where simulation adds the most value.
Prove It on Your Part
A guided demo, trial or pilot on a real component shows results before you commit.
License and Implement
Right-sized Altair Units or Siemens licenses, installation and workflow setup.
Train and Support
Custom training, engineering services and ongoing support as usage grows.
FAQ
Engineering Simulation Solutions FAQ
What Industries Rely on CAE Software?
Computer-aided engineering is used wherever failure is expensive: aerospace and defense, automotive and EV, medical devices, electronics and telecommunications, industrial machinery, energy and utilities, consumer products, civil structures and advanced manufacturing.
What Industries Does TrueInsight Support?
We support manufacturing, robotics, aerospace, drones, medical devices, automotive and advanced mobility, electronics, batteries and energy, using both Altair and Siemens technologies.
What Is Structural Analysis Used For?
To predict stress, deformation, vibration and failure risk under real loads so designs can be validated before manufacturing. It is usually performed with finite element analysis to find stress hot spots, excessive deflection, buckling risk and durability concerns early.
What Is the Difference Between Linear and Nonlinear Structural Analysis?
Linear analysis assumes small deformations and proportional material behavior, which suits many standard problems. Nonlinear analysis accounts for large deformation, contact, plasticity and material nonlinearity, which complex or highly loaded structures require.
Do I Always Need Meshing for Structural Simulation?
Most structural simulations divide geometry into finite elements, but meshless tools such as SimSolid analyze CAD assemblies directly for fast design studies. Read SimSolid vs HyperMesh: when you actually need a mesh.
Which Tool Is Best for Crash or Impact Simulation?
Crash and impact require an explicit dynamics solver such as Altair Radioss, which captures high-speed contact, large deformation and material failure. HyperMesh prepares crash-ready models and OptiStruct refines structures once crash results drive redesign.
What Is the Best Software for EMC Simulation?
For radiated EMC/EMI, antenna coupling and installed performance, a full-wave high-frequency solver such as Altair Feko is the usual choice. Circuit and PCB tools such as PSIM and PollEx catch layout and switching issues earlier, and Flux covers low-frequency fields in motors and transformers.
What Is the Best Thermal Simulation Software?
It depends on the stage. Simcenter FloEFD runs CAD-embedded thermal and airflow checks during design; Simcenter STAR-CCM+ handles detailed conjugate heat transfer and multiphysics; SimLab adds thermal to CAD-associated structural workflows. Learn more about Simcenter FloEFD.
What Is the Best Software for Flow Simulation?
For high-fidelity internal and external flow, multiphase and coupled physics, Simcenter STAR-CCM+ is a leading choice. FloEFD suits designers working inside CAD, FlightStream speeds early aerodynamics, and Altair CFD covers general flow inside the Altair Units ecosystem.
How Are Altair and Siemens Solutions Adapted to Different Industries?
Both portfolios are flexible and are configured to industry needs, from structural and fluid analysis to electromagnetics, data-driven engineering and optimization. We map the tools, templates and licensing to your products and processes.
Can TrueInsight Help Identify the Right Solution for My Business?
Yes. Our team works with you to understand your challenges and recommend the most effective tools and workflows. You can also start with the Solution Finder to compare 39 Altair and Siemens technologies.
Do I Need Simulation Experience to Get Started?
No. TrueInsight provides onboarding, training and guidance for teams at every experience level, and our engineering services can run the first analyses with you.
Can Solutions Be Integrated Into Existing Workflows?
Yes. Altair and Siemens tools import geometry from all major CAD systems and connect to PLM, so simulation can be added to your current engineering process without disrupting operations.
Does TrueInsight Provide Ongoing Support After Implementation?
Absolutely. We offer continuous support and licensing help, consulting and optimization services to keep performance improving after rollout.
Related Pages
Find the Right Simulation Software
Solution FinderMatch your engineering challenge to 39 Altair and Siemens technologies- Altair SoftwareSimulation, optimization, electromagnetics and AI
- Siemens PLM SoftwareNX, Solid Edge, Teamcenter and Simcenter
- Altair HyperWorksFEA and CAE platform for structural simulation
- Siemens SimcenterCFD, FEA, system simulation and test
- Structural Analysis SoftwareFEA, nonlinear, crash and optimization tools
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