The industrial sector like many others, is undergoing a huge transformation. A confluence of technologies, ranging from electrification and autonomy to additive manufacturing and robotics, is redefining how products are conceived, developed and deployed. At the centre of this shift is the growing need to manage unprecedented levels of complexity in both product design and system integration.
Simulation becomes a core engineering capability
Simulation, once confined to the later stages of engineering workflows, has emerged as a foundational capability that enables development teams to navigate this complexity. It allows engineers to predict real world behaviour early in the design process, reducing reliance on costly prototypes and accelerating innovation across sectors. The application of multiphysics simulation - modelling thermal, structural, fluid and electromagnetic interactions together - has become critical in developing products that must meet performance expectations across a wide range of operating conditions.
Across the industrial landscape, companies are facing increasing pressure to develop intelligent, software defined products. These systems, which may include anything from autonomous drones to connected appliances and heavy machinery, require the integration of sensors, electronics and embedded software. This integration brings with it layers of system level challenges that are difficult to address through conventional methods. Simulation technologies, when combined with virtual testing environments such as hardware in the loop and software in the loop, are enabling developers to evaluate complex interactions much earlier in the design lifecycle.
Managing early-stage complexity with virtual tools
This early-stage exploration not only supports the testing of ‘what if’ scenarios but also provides greater scope for optimisation and customisation. By creating high fidelity digital prototypes, engineering teams can explore how different subsystems interact, validate control algorithms, and ensure that designs are robust before committing to physical builds. These capabilities are becoming especially important in sectors where reliability, safety and performance must be assured over long operational lifespans.
A maturing digital ecosystem supports scalability
To support the increasing demands of fifth generation industrial development, several technological pillars are converging to create what can be described as a digital engineering ecosystem. High performance computing is providing the capacity to run large-scale simulations and process complex data sets quickly. Artificial intelligence and machine learning are being applied to accelerate design optimisation, automate routine analysis tasks and identify patterns in data that would be difficult to detect manually. Cloud computing and IoT platforms are enabling remote collaboration and access to real-time operational data, while digital twins are being used to create live models that reflect the state and performance of physical systems.
Together, these technologies are allowing organisations to scale their engineering capabilities well beyond what traditional tools can offer. This concept, often referred to as digital hyperscaling, involves the ability to develop, deploy, and evolve digital models at pace and at scale. It enables teams to respond quickly to shifting requirements, adapt designs for new use cases, and extend the utility of digital assets across product lifecycles.
Wider industrial applications of simulation and digital twins
In sectors such as advanced manufacturing, smart infrastructure, industrial automation and transportation, the ability to simulate and test complex systems virtually is becoming a strategic differentiator. Whether in the development of next-generation rail systems or offshore wind infrastructure, the integration of physics-based modelling with real-time data is improving design fidelity, reducing development costs, and shortening time to market. For original equipment manufacturers, this means being able to meet increasingly complex customer demands while also managing risk and ensuring compliance with stringent regulatory standards.
Moreover, simulation is no longer confined to the design office. It is extending into operations and maintenance using digital twin technology. These dynamic models, informed by live sensor data, allow operators to monitor system performance in real time, predict maintenance needs, and optimise usage over time. By closing the loop between design and operation, engineers can continue to refine and improve systems after deployment, creating a continuous feedback cycle that enhances performance and extends asset life.
Driving innovation through AI and generative design
As simulation tools become more sophisticated, they are also playing a central role in generative design processes. By applying AI-driven algorithms to large design spaces, engineers can uncover new geometries and configurations that meet specific performance criteria. These techniques are particularly effective in additive manufacturing, where complex shapes can be fabricated directly from digital models. Simulation ensures that these novel designs meet structural and functional requirements before production begins.
Shaping the future of engineering through digital integration
The result is a more agile and resilient approach to engineering - one that combines physics - based understanding with data science, cloud platforms and artificial intelligence to accelerate innovation and improve outcomes. As the boundary between the physical and digital continues to blur, simulation is enabling engineering teams to make better-informed decisions at every stage of the product lifecycle.
The next industrial transition is not defined by any one technology, but by the integration of many. Simulation, supported by scalable digital infrastructure and informed by real-world data, is now a cornerstone of that transformation. It empowers engineers to anticipate behaviour, optimise designs and ultimately deliver smarter, more reliable systems for a rapidly changing world
Scott Parent, VP and Field CTO, Energy, Aerospace, Semiconductor, and Industrial, Ansys
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