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AT A GLANCE

During product development, we’ll support you with the timely and efficient analysis of the strength of your designs. If necessary, we’ll create computational strength assessments based on the latest technologies and provide reliable technical reports for the certification of your products.

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Structural analysis

Each project starts with the structure analysis of your product based on a finite element model created by us – preferably based on your CAD data. This model identifies how forces act on your component, where excessive stress occurs and where there are any weak points. 

Almost any material – whether metal, plastic, or of biological origin – can be analysed. 

If nonlinear material behaviour, contacts, or large deformations result in nonlinearities, we include these in our calculations.

Structalys provides the following analyses:

  • Deformation analysis
  • Stress analysis
  • Strength analysis (static, fatigue)
  • Stability analysis (buckling)
  • Dynamic analysis (vibration, impact, crash)
  • Thermal analysis (temperature distribution)
  • Thermo-mechanical analysis (thermal strain and stress)

Für Analysen mit Fluiddynamik (CFD), Akustik oder Elektromagnetismus können wir auf die Zusammenarbeit mit Spezialisten in Hochschulen und befreundeten Firmen zählen.

Computational proof of strength

We know all the current standards and regulations and have many years of experience in applying them. The result? A well-founded, legally valid proof of the static strength and fatigue resistance of your parts. The strength assessment is based on a preceding finite element analysis. Machine parts made of steel, cast iron and aluminium can be calculated and proved using the method stipulated by the German FKM guideline, based on local structural stresses.

Special requirements are not a problem either: we’re happy to consider customer-specific and industry-specific procedures and regulations like EN 1993, AD 2000, and ASME. 

A regulatory technical report containing all the relevant data thus forms the basis of the certification of your product.

From analysis to certification

Structalys can assist you from the start of the design process to product certification – or as needed during specific project phases. How do we work? Based on your CAD geometry model, we create complete calculation models and calculate relevant local variables such as deformation, stress, strain and temperature. We then help you to interpret the results and look for possible optimisations, considering all relevant standards and regulations.

If your component complies with all the necessary requirements, we will provide you with a technical report. If you wish, we can also take care of the next step in the approval procedure. Years of experience and ongoing further education and training guarantee that we’ll reach your goal together, quickly and efficiently.

From shape optimisation to 3D printing

What shape should your component be to ensure that it’s as lightweight as possible, while still being sufficiently strong and stiff? Structalys will calculate the optimal structure using modern expert-software and a finite element model designed especially for this purpose. Similar to bone structure in nature, each part should only feature added material where localised stress demands it. We’ll then examine the strength of the new, optimised 3D design and its robustness regarding potential manufacturing and assembly tolerances.

New 3D printing processes are used for producing these designs, as they’re already used in the aerospace and automotive industries. This applies to structures made of various plastics, as well as aluminium and steel alloys, and other metals. We can assist you in finding a 3D printing solution for your component and will provide all the necessary data for your geometry model in the appropriate format (STL).

Efficient best-practices

No component is too complex: Structalys is your specialist for complex calculations. Nonlinear finite element analysis is one of our core competencies, whereby we only apply the effort that is necessary to get results – nothing more and nothing less. 

This ranges from simple formula calculations to complex dynamic analyses with nonlinearity, such as those resulting from large deformations, friction contacts and plastic material behaviour.

Your secrets are safe with us

No research or progress is possible without trade secrets. At Structalys, we see ourselves as part of the innovative
technology sector and guarantee the utmost discretion. With us, your sensitive data is in good hands.

Finite element analysis

When it comes to machine parts and supporting structures with simple geometry, stresses can be identified quickly – analytical formulas and manual calculations often suffice. However, this is not the case for complex components. Here, numerical simulations are needed to obtain reliable information on strain and strength. This is where finite element analysis comes in, as it allows us to precisely and accurately determine the strength of complex components. To complete the analysis, we first split your component into ‘finite elements‘, i.e. into small partial bodies, ideally based on a CAD geometry model. We can then precisely calculate the stress on these small-structured geometries. The finite elements analysis (FE analysis) is then applied to the component through numerical integration and the computationally formulated addition of each finite element’s stiffness to the stiffness matrix of the entire component. The resulting equation system often consists of several million unknowns. Powerful computers can perform such tasks and deliver meaningful results.

Whether temperatures and strains, or pressure and forces, FE analysis provides information about each physical process in a solid state. This makes it possible to quantify tensions and heat distribution relatively accurately in a solid object.

Finally, a graphical model illustrates the results of the FE analysis. Thanks to the colour distribution in contour plots, a component’s critical areas are immediately recognisable. For example, blue and green tones could represent stable zones, while orange to light red areas are subject to increased loads. Finally, deep red serves to highlight hotspots, where the component is no longer sufficiently strong.

Thanks to these findings, components can be optimised during the design process – thus saving you time and reducing development costs! In addition, the results of the analysis serve as proof of the component’s safety.