Run stress tests, find weak points with FEA, and let generative design create shapes you'd never imagine.
Simulation predicts how parts behave under real-world conditions before manufacturing. Topology optimization and generative design let algorithms propose lighter, stronger geometry than hand-design.
FEA divides a solid model into thousands of elements (a mesh), solves physics equations on each, and predicts how the part responds to forces, pressures, and temperatures.
Where do you think the highest stress will appear on a cantilever beam loaded at the tip?
FEA (Finite Element Analysis) divides a part into small elements and solves stress/strain equations for each.
Safety Factor = Material Yield Strength / Max Stress. Values > 1.0 mean the part survives. > 2.0 is typical for robotics.
Key inputs: material, loads, constraints (fixed faces), mesh size.
Red = high stress. Blue = low stress. Concentrate on the transition zones.
Topology optimization carves away non-load-bearing material from a solid block, leaving an organic structure that is as light as possible while meeting stiffness and strength requirements.
Generative design extends topology optimization by generating dozens of alternatives, each tailored to a specific manufacturing process and material.
Heat Transfer: Thermal FEA simulates conduction, convection, and radiation to verify electronics stay within operating temperature and size heat sinks.
Modal Analysis: Calculates natural frequencies and mode shapes. Keep the first natural frequency at least 20% away from operating frequencies to avoid resonance.
Follow this process for any simulation study.
Choose the analysis type (static, modal, thermal) and assign accurate material properties to every body.
Constrain the model as held in reality and apply all forces, pressures, and moments.
Create the element mesh, refine in critical areas, and run the solver.
Review stress, displacement, and safety-factor plots to identify problem areas.
Modify the design based on results and re-run until all requirements are met with minimum weight.
Knowing what to look at and what the numbers mean is critical for sound engineering decisions.
| Result Type | What It Shows | Key Guidelines |
|---|---|---|
| Stress Color Map | Blue = low stress, green = moderate, yellow = approaching yield, red = at or above yield strength | Focus on red zones. If red appears only at a sharp corner or point load, it may be a stress singularity (a mesh artifact) -- refine the mesh and re-check. |
| Displacement Plot | How much each point of the part moves under load (shown exaggerated for visibility) | Check that maximum deflection is within your tolerance. For robot arms, even 0.5mm of tip deflection can affect accuracy. |
| Safety Factor | Ratio of yield strength to actual stress at each point | Minimum 1.5 for static loads on well-understood parts. 3-4 for dynamic, impact, or fatigue loads. Below 1.0 means the part will yield (permanent deformation). |
| Convergence Check | Whether the solution has stabilized as mesh density increases | Run at least 2-3 mesh refinement levels. If peak stress changes more than 5-10% between levels, the mesh is too coarse and results are unreliable. |
| Mode Shapes (Modal) | The deformation pattern at each natural frequency | Ensure the first natural frequency is at least 20% away from any motor or drivetrain operating frequency to avoid resonance. |
Planetary Gear Set — sun gear, three planet gears on a carrier, and a ring gear with internal teeth. A compact, high-torque-density transmission common in servo gearboxes.
Optimize a robot arm bracket for weight using topology optimization or manual lightening.