Static & Nonlinear FEA | Plastics and Metals

What we do

We predict real-world deformation and failure for plastics and metals using static & nonlinear FEA. From snap-fits and living hinges to brackets, welds, and adhesive joints, we model large deflection, contact, plasticity, hyperelasticity, creep, and buckling—then translate results into clear design changes suppliers can build.

Outcomes we target

  • Verified safety factors and displacement limits under true boundary conditions
  • Accurate permanent set and strain hot-spots (not just linear stress)
  • Robust snap-fits/hinges with open/close life and assembly force targets
  • Reduced weight/cost while meeting strength & stiffness requirements

Services

  • Linear → Nonlinear Upgrade – baseline linear checks, then add geometric/material/contact nonlinearity where it matters.
  • Material Modeling & Calibration – true stress-strain conversion, plasticity (bilinear/multilinear, isotropic/kinematic), hyperelastic (Neo-Hooke, Mooney-Rivlin, Ogden), viscoelastic (Prony), creep.
  • Contact & Assembly – frictional/contact pairs, fastener preload, interference fits, snap-fit engagement, adhesive layers (cohesive zone).
  • Buckling – eigenvalue (linear) and nonlinear/arc-length (Riks) to capture post-buckling behavior.
  • Rate/Temperature Effects – strain-rate sensitive plastics and temperature-dependent moduli/yield; thermal-mechanical coupling if needed.
  • Joints & Welds – bolted joints with preload/relaxation, spot/fillet weld representation, bonded/adhesive failure envelopes.
  • Design Optimization – thickness/rib tuning, bead patterns, local radii/fillets, material swaps.
  • Test Planning & Correlation – fixture concepts, load cases, gauges/strain rosette placement, acceptance criteria.

Deliverables you receive

  • Engineering Report (PDF) – scope & assumptions, meshes, material cards, load cases/BCs, results with hot-spot callouts, risk ranking, and actionable design recommendations.
  • Solver Decks & Post Files – ANSYS/Abaqus/LS-DYNA models, load steps, contact definitions, and post templates.
  • Material Cards – calibrated parameters for plastics/metals (EN/DE datasources noted), temperature/rate tables.
  • CAD Markups – ribs/fillets/thickness, snap-fit geometry, fastener/adhesive notes.
  • Validation Plan – proposed tests, sensor layout, correlation matrix.
  • Handover Session – 45–90 min walkthrough + Q&A with your team.

Technical stack

  • Solvers: ANSYS Mechanical, Abaqus Standard/Explicit, LS-DYNA
  • Pre/Post: Workbench, HyperMesh/ANSA, Meta/Post, Python notebooks
  • Analyses: linear/static, geometric nonlinearity, plasticity, hyperelastic/viscoelastic, creep, contact, buckling (eigen + Riks)
  • Materials: ABS/PC/PA/PP/POM, elastomers/TPU, glass-filled plastics, steels/Al/Mg/Ti; optional orthotropy if data provided
  • Features: snap-fits/living hinges, inserts/bosses, welds, adhesives, threaded joints

How an engagement works

  1. Discovery (30 min) – targets, constraints, load cases, acceptance metrics.
  2. Data & Setup – CAD, materials, joints; mesh and contact strategy; material calibration plan.
  3. Simulation – baseline → nonlinear → sensitivity/what-ifs; buckling if relevant.
  4. Recommendations – prioritized design actions with expected effect on KPIs.
  5. Validation – optional lab correlation and final report/update.

What we need from you

  • CAD (STEP/Parasolid) and assembly details (fasteners, adhesives, inserts)
  • Material datasheets or test curves (tension/compression; DMTA for elastomers if available)
  • Load/constraint definitions, duty cycles, temperature range
  • Success criteria: SF ≥ X, max deflection ≤ Y, permanent set ≤ Z, cycles to failure, etc.

Packages

  • Nonlinear Assessment – convert linear study to nonlinear with calibrated materials; quick risk list.
  • Simulation Sprint – full nonlinear model (contact/plasticity/hinges), buckling as needed, report + CAD markups.
  • Correlation & Optimization – test plan, sim↔lab update, weight/cost optimization.

Example use cases

  • Snap-fit lid: reduce assembly force, protect latch roots, predict permanent set after 100 cycles.
  • Bracket (metal): capture plastic hinges, improve SF via local radii and bead stiffening.
  • Adhesive joint: cohesive zone model to size bond width and fillet; peel/shear envelopes.
  • Thin cover: nonlinear Riks buckling to avoid oil-canning under pressure/handling.

FAQ

Do you create material cards if we don’t have test data?
Yes—using credible datasheets and literature; we note assumptions and add sensitivity bands. Best accuracy comes with your test curves.

Can you handle insert molding and creep in plastics?
We model insert interfaces and long-term creep/relaxation where needed, with temperature/rate effects.

How do you avoid over-stiff contacts?
By using proper contact formulation, penalty settings, and mesh refinement; we verify with convergence checks.

Will we get the FEA files?
Yes—complete decks and post templates are included.

Do you support anisotropy/fiber orientation?
If orientation data is available, we can incorporate orthotropic behavior or weld line reductions.