Step
Requirement & Reference Study
Fit, function, materials and constraints defined before any geometry is drawn.
Finite Element Analysis (FEA)
FEA that answers a real engineering question, not a checkbox on a proposal.
Structural and thermal finite element analysis for enclosures, brackets, actuators and load-bearing assemblies, used to validate a design decision before it is committed to tooling or machining.
Clear scope, editable files, practical handoff
The service page explains the risk it solves, the deliverables included and the workflow used to reach a production-ready result.
Where this usually goes wrong
FEA run without a clear question in mind (a validated boundary condition, a real load case, a target Factor of Safety) produces a pretty stress-color plot and not much else. Simulation is only useful when it is tied to an actual decision that needs making.
What you get
- Structural FEA: stress, deflection and Factor of Safety against real load cases
- Thermal FEA: steady-state and transient temperature studies
- Boundary condition and load case definition tied to actual use conditions
- Mesh convergence checks so results can be trusted, not just generated
- A clear written summary: pass/fail against target, and what to change if it fails
- Iteration support: rerun analysis as the design changes
How it works
A practical five step workflow.
Every stage produces a clear decision, review point or manufacturing deliverable.
Step
Concept CAD & DFM Review
Parametric modeling reviewed early for moldability, machinability and assembly.
Step
Detailed Modeling & Simulation
Full assemblies, tolerancing, and FEA/thermal validation where load or heat matter.
Step
Manufacturing Drawings & GD&T
Dimensioned packages, flat patterns, BOMs and tolerance callouts a supplier can quote.
Step
Prototype & Handoff
Prototypes confirm fit and function, then final files are packaged for production.
Proof, not promises
A related project example.
The portfolio example shows how the same engineering decisions appear in completed work.
Project 04
EV Battery Pack Enclosure
An EV battery pack enclosure machined from 6061 T6 aluminum, where Ansys Thermal and Ansys Mechanical studies indicated a 55.3°C peak temperature and a 132.6 MPa peak stress, both inside spec, validating a structural Factor of Safety of 2.4 before the manufacturing drawing was released.
View portfolioCommon questions
Do you use SolidWorks Simulation or Ansys?
Both, depending on the project. SolidWorks Simulation covers most structural and thermal validation; Ansys is used where a higher-fidelity study is warranted.
Can FEA be run on a design I already have, or only new CAD?
Yes, running FEA on an existing model, including cleaning up geometry so it meshes properly, is a common standalone request.
How do you decide what load case to use?
Load cases are defined from the product's actual use conditions wherever possible, not generic assumptions, and any assumption made is stated clearly in the results.
What does the final deliverable look like?
A written summary tied to a clear pass/fail against a target Factor of Safety or temperature limit, alongside the stress/thermal plots themselves, not just colorful images with no conclusion.
Can you validate a part is safe before I commit to CNC machining or tooling?
Yes, that is one of the most common and valuable uses of FEA, catching an undersized section or a stress concentration before it becomes an expensive mistake in metal.
Related options
Services that commonly work together.
Use these pages to compare scope and deliverables before combining services into one project.
Discuss this service
Share the current design problem.
I’ll review the available information and suggest a practical first milestone.