Introduction
How do we know if a new airplane wing can withstand a storm without actually building it and subjecting it to extreme winds? The answer is Finite Element Analysis (FEA). FEA is a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects.
In the Product Lifecycle Management (PLM) process, FEA is the primary tool for structural validation. It allows engineers to “see” where a part will bend or break long before it is manufactured. By simulating these physical behaviors, companies can optimize designs for safety and performance while drastically reducing the need for physical “crash tests.”
How FEA Works: The Power of the “Finite Element”
The core concept of FEA is to simplify something complex into something manageable. It follows a structured process:
- Discretization (Meshing): The complex 3D geometry of a product is divided into thousands of small, simple shapes called Finite Elements. Together, they form a Mesh.
- Applying Physics: Mathematical equations (typically partial differential equations) are applied to each element to predict its behavior.
- Boundary Conditions: Engineers define external forces, such as gravity, pressure, or fixed points where the part is bolted down.
- The Assembly of Results: The software solves all the equations simultaneously to show the overall reaction of the entire object.
Key Types of FEA Simulations
- Static Analysis: Determines displacement, stresses, and strains under steady loads.
- Dynamic Analysis: Tests how the product reacts to moving loads, vibrations, or sudden impacts (like a drop test).
- Thermal Analysis: Simulates temperature distribution and the resulting thermal expansion or stress.
- Fatigue Analysis: Predicts the life expectancy of a product by simulating repeated loading and unloading cycles over time.
Strategic Benefits for the PLM Workflow
| Benefit | Impact on Product Success |
| Optimized Weight & Material | Identify “low-stress” areas where material can be removed to save weight and cost (Generative Design). |
| Enhanced Safety | Find “hidden” stress concentrations that could lead to catastrophic failure. |
| Regulatory Compliance | Provide documented proof that a design meets industry safety factors (e.g., Aerospace or Medical). |
| Faster Iterations | A change in the CAD model can be re-analyzed in minutes, ensuring the design evolves rapidly. |
How Visure Solutions Anchors FEA in the Digital Thread
The biggest challenge in FEA is ensuring that the simulation reflects the actual requirements of the product. Visure Requirements ALM Platform bridges this gap:
- Requirement-to-Analysis Traceability: Link a specific safety requirement (e.g., “The bracket must support 200kg with a safety factor of 1.5”) directly to the FEA report.
- Closed-Loop Verification: When the FEA results show that the stress levels are within limits, Visure automatically marks the requirement as “Verified.”
- Version Control for Simulations: As the design changes, Visure ensures that the FEA is run on the latest version of the CAD, preventing validation errors.
- Cross-Domain Impact: If an FEA result requires a thicker part, Visure helps analyze how that extra weight impacts other requirements, such as battery life or shipping costs.
Conclusion
Finite Element Analysis (FEA) is the difference between guessing and knowing. It provides a level of mathematical certainty that allows for bolder innovation and safer products. Within a mature PLM environment, FEA isn’t just a technical task; it’s a strategic asset that protects the company from liability and ensures customer trust.
By integrating FEA validation into Visure, you turn complex simulation data into actionable business intelligence. You ensure that every product you release isn’t just “well-designed,” but is structurally guaranteed to perform under the toughest conditions the real world can throw at 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.
