3D FEA simulation of material flow reduced custom profile development time from 12 weeks to 3 weeks for an automotive supplier.
The Challenge
An automotive sensor supplier needed a new custom-profiled wire. Their previous supplier's trial-and-error method resulted in 12-week lead times and wasted material.
Titan Engineering Solution
Titan implemented an end-to-end Digital Twin process. We simulated the material flow, stress distribution, and wear points in 3D FEA software before cutting a single piece of carbide.
Fig 1. Analysis and Implementation
The Results
The simulation accurately predicted a flow issue, which we corrected in the digital model. The first physical die required only minor polishing. Development time dropped from 12 weeks to 3 weeks.
Key Takeaways
- Digital twins identify defects before manufacturing.
- Simulation drastically reduces development lead time.
- Virtual prototyping saves expensive raw material.
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