Static and Nonlinear FEA – Plastics and Metals

What we do

We predict deformation and failure of plastics and metals under real-world boundary conditions using static and nonlinear FEA. From snap-fits and film/living hinges to brackets, welds, and adhesive joints, we model large deformations, contact, plasticity, hyperelasticity, creep, and buckling — and then translate the results into clear design changes that your suppliers can actually manufacture.

Target outcomes

  • Verified safety factors and deformation limits under realistic loads and boundary conditions

  • Accurate prediction of permanent set and strain hotspots — not just linear stress plots

  • Robust snap-fits and hinges with targets for lifetime (open/close cycles) and assembly forces

  • Weight and cost reduction while meeting stiffness and strength requirements

Services

  • Linear-to-nonlinear upgrade — we start from existing linear checks and then add geometric, material, and contact nonlinearity where the response truly changes.

  • Material modeling & calibration — true stress–strain curves; plasticity (bi-/multilinear, isotropic or kinematic); hyperelasticity (Neo-Hooke, Mooney–Rivlin, Ogden); viscoelasticity (Prony series); and creep behavior.

  • Contact & assembly — frictional contact pairs, bolt pretension, press/interference fits, snap engagement, and adhesive layers using cohesive zone models.

  • Buckling — linear eigenvalue buckling plus nonlinear arc-length (Riks) analyses to capture post-buckling behavior.

  • Strain-rate and temperature effects — rate-sensitive plastics and temperature-dependent modulus/yield limits, including thermo-mechanical coupling where required.

  • Joints & welding — bolted joints with pretension and relaxation, modeling of fillet and spot welds, adhesive joints with failure envelopes.

  • Design optimization — wall thickness and rib tuning, bead patterns, local radii/blends, and material variants.

  • Test planning & correlation — test setups, load cases, measurement concept (strain gauges, DIC), and acceptance criteria.

Your deliverables

  • Engineering report (PDF) — scope and assumptions; meshes; material cards; load cases and boundary conditions; results with hotspot markers; risk ranking; and concrete design recommendations.

  • Solver decks & post-processing files — runnable models for Ansys, Abaqus, or LS-DYNA including load steps, contact definitions, and post-processing templates.

  • Material cards — calibrated parameters for plastics and metals (with EN/DE data sources documented), including temperature and strain-rate tables where relevant.

  • CAD markups — suggested changes to ribs, radii, wall thicknesses, snap geometries, and joint details (bolts, bonding).

  • Validation plan — recommended tests, sensor layout, and a correlation table between simulation and lab.

  • Handover session — 45–90 minute live walkthrough and Q&A with your team.

Technology stack

  • Solvers: Ansys Mechanical, Abaqus Standard/Explicit, LS-DYNA

  • Pre/Post: Workbench, HyperMesh/ANSA, Meta/Post, plus Python-based notebooks

  • Analyses: linear statics, geometric nonlinearity, plasticity, hyper- and viscoelasticity, creep, contact, and buckling (eigenvalue and Riks)

  • Materials: ABS, PC, PA, PP, POM, elastomers and TPU, glass-fiber reinforced plastics, steels, aluminum, magnesium, and titanium; optionally with orthotropy if orientation data is available

  • Features: snap-fits and living hinges, inserts and bosses, welds, adhesive joints, and threaded connections

Typical project flow

  • Discovery (~30 minutes) — goals, boundary conditions, load cases, and acceptance criteria

  • Data & setup — CAD and materials; joints and joining concepts; meshing and contact strategy; plan for material calibration

  • Simulation — baseline (linear) checks, then nonlinear runs and sensitivity/what-if studies; buckling analysis where relevant

  • Recommendations — prioritized design actions with expected impact on your KPIs

  • Validation — optional lab correlation and finalization of report and models

What we need from you

  • CAD data (STEP/Parasolid) and joint details (bolts, bonding, inserts, welds)

  • Material datasheets or test data (tension/compression; optionally DMTA for elastomers)

  • Definitions of loads and boundary conditions, load spectra/duty cycles, and relevant temperature range

  • Success criteria: required safety factors, max allowable deformation and permanent set, target cycles to failure, and customer-specific or normative limits

Packages

  • Nonlinear assessment — upgrade an existing linear analysis with the relevant nonlinearities, calibrated materials, and a concise risk list.

  • Simulation sprint — full nonlinear model (contact, plasticity, living hinges), buckling analysis as needed, plus report and CAD markups.

  • Correlation & optimization — test plan, simulation-to-lab correlation, plus weight and cost optimization.

Example applications

  • Snap-on lid — reduced assembly force, protection of notch-root areas, and prediction of permanent deformation after 100 open/close cycles.

  • Metal bracket — capture plastic hinge behavior and increase safety factor via local radii and beads.

  • Adhesive joint — cohesive zone modeling to size bond width and fillet, with peel and shear failure envelopes.

  • Thin cover sheet — nonlinear Riks buckling analysis to avoid “oil canning” under pressure or handling.

FAQ

Do you create material cards if we don’t have test data?
Yes. We can derive material cards from reliable datasheets and literature. Assumptions are clearly documented and we add sensitivity bands. The best accuracy comes from your own test curves.

Can you model insert molding and creep in plastics?
Yes. We model insert interfaces as well as long-term creep and relaxation in plastics — including temperature and strain-rate effects where required.

How do you avoid overly stiff contact behavior in the simulation?
With appropriate contact formulations and penalty settings, locally refined meshes, and proper convergence checks.

Do we get the FEA files?
Yes. You receive the complete solver decks and post-processing templates.

Do you support anisotropy and fiber orientation?
Where orientation data is available, we can account for orthotropic material behavior and include effects such as strength reductions at weld lines.

Contact us