Introduction
In the modern industrial landscape, testing and simulation are no longer isolated departmental tasks; they are the heart of a comprehensive Quality Governance strategy. An Overview of Testing and Simulation in PLM reveals a shift from fragmented validation to an integrated approach where data flows seamlessly between the digital model and the physical prototype.
The primary goal of this integrated approach is to answer two fundamental questions early and often:
- Verification: Are we building the product right? (Does it meet the technical specifications?)
- Validation: Are we building the right product? (Does it satisfy the user’s actual needs?)
By managing both questions within the PLM framework, organizations can ensure that quality is “baked in” from the first requirement to the final certification.
The Spectrum of Validation: From Virtual to Physical
A modern PLM testing strategy doesn’t choose between simulation and physical testing; it orchestrates a hybrid approach that leverages the strengths of both.
1. The Virtual Domain (Simulation)
Early in the lifecycle, simulation dominates. It allows for rapid iteration and “what-if” analysis.
- Key Tools: FEA, CFD, and Thermal Simulation.
- Value: Identifying design flaws when the cost of change is at its lowest.
2. The Hybrid Domain (Hardware-in-the-Loop)
As the design matures, we combine digital and physical elements. Hardware-in-the-Loop (HiL) testing allows engineers to test real electronic control units (ECUs) against a virtual simulation of the rest of the vehicle or aircraft.
- Value: Validating complex software interactions before a full physical system is available.
3. The Physical Domain (Final Testing)
Physical testing remains the “Gold Standard” for final certification and safety validation.
- Key Tools: Crash tests, wind tunnel sessions, and field trials.
- Value: Providing the final proof of safety and durability required by law and customers.
The Testing & Simulation Workflow in PLM
To manage this complexity, PLM systems implement a structured workflow that ensures no requirement is left untested:
| Phase | Activity | Outcome |
| Requirements | Test Plan Definition | Defining success criteria before design starts. |
| System Design | Model-Based Simulation | Verifying functional logic through MBSE. |
| Detailed Design | High-Fidelity Simulation | Stress, fatigue, and fluid dynamics analysis. |
| Prototype | Physical Validation | Correlation of virtual results with real-world data. |
| Operations | Continuous Testing (IoT) | Monitoring performance and aging in the field. |
Why “Simulation Data Management” (SDM) is Critical
One of the biggest hurdles in a testing overview is the sheer volume of data. A single simulation can generate terabytes of information. Without Simulation Data Management (SDM) within the PLM:
- Results get lost in personal hard drives.
- Analysts work on outdated versions of the CAD model.
- There is no traceability between a test failure and the requirement that caused it.
How Visure Solutions Orchestrates the Testing Overview
Visure Requirements ALM Platform acts as the overarching “Validation Hub” that connects the dots between the virtual and physical worlds:
- Unified V&V Matrix: Visure provides a single view of all testing activities. Whether it was a virtual FEA test or a physical stress test, the result is captured and linked to the original requirement.
- Test Case Reusability: Visure allows teams to define test cases once and apply them across virtual simulations and physical trials, ensuring consistency.
- Automated Traceability Audit: For regulated industries, Visure automatically generates the evidence that every requirement has been verified by at least one test (virtual or physical).
- Gap Analysis: Visure instantly identifies “Uncovered Requirements”—those that haven’t been assigned a test case yet—preventing late-stage surprises.
Conclusion
The Overview of Testing and Simulation demonstrates that modern engineering success is a balancing act. Simulation provides the speed and cost-efficiency needed to innovate, while physical testing provides the certainty and safety required for the real world.
An effective PLM strategy doesn’t treat these as separate silos. By using a platform like Visure to maintain a “Digital Thread” of requirements across both domains, companies can move forward with confidence. When your simulation data, test results, and requirements are all synchronized, you don’t just hope the product works—you have the data to prove it.
Check out the 14-day free trial at Visure and experience how AI-driven change control can help you manage changes faster, safer, and with full audit readiness.
