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FEA & CAE — Design, Verification & Optimization.

ProSIM provides sophisticated multi-physics simulations alongside expert finite element analysis, turning intricate data into practical insights that drive smart design choices. By thoroughly evaluating simulation outcomes, our experienced team applies deep technical knowledge to craft reliable answers to the most challenging engineering puzzles.

Finite element analysis — stress and multi-physics results
FEA & CAE
Non-linear FEA model detail
OUR EXPERTISE

Simulation That Drives Design Decisions

From design optimization and seismic qualification to structural integrity, remaining-life assessment, failure analysis and multi-physics modelling, ProSIM converts simulation data into actionable engineering direction.

Simulation-Driven Engineering Services

ProSIM provides sophisticated multi-physics simulations alongside expert finite element analysis, turning intricate data into practical insights that drive smart design choices. The rigorous evaluation of simulation data through our specialized services allows us to facilitate the following:

01

Design Optimization

Streamlining products through parametric, topology, shape, and sizing refinements.

02

Seismic Evaluation & Qualification

Ensuring designs meet the strict requirements of international industry standards and safety codes.

03

Structural Integrity Assessment

Gauging a product's factor of safety, stiffness, and overall strength when subjected to real-world operating environments.

04

Remaining Life Assessment & Extension (RLA/RLE)

Conducting comprehensive asset longevity evaluations and Fitness-for-Service (FFS) analyses.

05

Component & System Life Assessment

Predicting long-term durability and evaluating potential fatigue life.

06

Failure Analysis

Identifying the root causes of breakdowns and offering actionable, corrective design modifications via our dedicated consulting team.

07

Localization & Indigenization

Modifying international product blueprints to comply with regional manufacturing rules and regulatory demands.

Core Technical Capabilities

Our engineers rely on a powerful combination of leading commercial platforms and versatile open-source programs to execute premium computer-aided engineering across diverse fields. We possess deep technical proficiency in Code_Aster, Radioss, OptiStruct, Nastran, Abaqus, and ANSYS, which allows us to perform:

01

Linear Static Analysis

Verifying design adequacy and confirming that stress levels remain within allowable limits.

02

Dynamic Analysis

Investigating transient, harmonic, and modal dynamic behaviors.

03

Frequency & Time Domain Analysis

Executing response spectra, frequency response, and time-series evaluations.

04

Non-Linear Analysis

Tackling complicated contact mechanics, significant geometric deformations, and material non-linearities.

05

Coupled Multi-Physics

Modeling complex phenomena such as fluid-structure interactions and thermo-mechanical effects.

Offshore CAE Services — Bangalore Delivery Center

Operating out of our specialized engineering hubs as a top-tier provider in India, we manage complete simulation lifecycles for clients around the world. Our Bangalore-based delivery center acts as a scalable, dependable resource for localized or offshore engineering support. When you outsource your finite element workflows to us, the process includes:

01

Pre-Processing

Detailed finite element modeling, meticulous meshing, and geometric cleanup using industry staples such as AutoCAD, CATIA, Solidworks, and Hypermesh — with dedicated Hypermesh capabilities for an incredibly accurate model configuration.

02

Quality Assurance

Rigorous oversight of quality metrics, mesh density, and element sizing to perfectly match the unique demands of each analysis.

03

Analysis Setup

Carefully configuring boundary conditions, validating mass balances, and establishing proper deck settings.

04

Solver Execution & Post-Processing

Processing the simulation solvers and interpreting the resulting data to yield strategic, actionable advice.

Onsite CAE Consulting & Placement

Our onsite placement program brings highly trained ProSIM professionals directly into your workspace. Functioning as resident consultants or application engineers, our staff blends into your existing operations and can even engage face-to-face with your clientele. After rigorous cross-training in the necessary domain applications, we offer highly targeted onsite assistance in:

01

FEA/CAE Solvers

Onsite specialists equipped to handle specific solver platforms, including comprehensive Radioss, OptiStruct, and ANSYS services right at your facility.

02

CAD Tools

AutoCAD, CATIA, and Solidworks.

03

Piping Engineering

CAESAR II and PEPS.

Dedicated CAE Outsourcing

By establishing Master Service Agreements (MSAs), clients guarantee steady, long-term engineering bandwidth. ProSIM collaborates with major international corporations, supplying focused teams to handle continuous project demands.

01

Master Service Agreements

Long-term MSAs that lock in predictable engineering capacity for continuous project pipelines.

02

Dedicated Solver Partnerships

An exclusive ANSYS partner, or broad-spectrum simulation outsourcing — we adapt our scale to your needs.

03

Continuous Workload Management

Ongoing multi-physics evaluations, preprocessing tasks, and meshing requirements handled as a managed service.

CODES & STANDARDS

Industry Codes & Standards Compliance

We meticulously validate your engineering designs to guarantee they satisfy rigorous, sector-specific global regulations.

StandardScope
ASMEB&PV — Boiler and Pressure Vessel Code.
APIAmerican Petroleum Institute standards.
EN / ISOEuropean and International Standards.
IEEEInstitute of Electrical and Electronics Engineers.
DNVGLMaritime and Offshore Standards.
INDUSTRY SECTORS SERVED

Industry Sectors Served

Our comprehensive simulation offerings provide deep, sector-specific knowledge, supporting critical, high-stakes industries across the globe.

Energy — nuclear, wind, offshore, oil & gas, and thermal power initiatives.
Aerospace & Defence — impact tests, dynamic qualifications, and structural weight minimization.
Automotive — component weight reduction with NVH, durability, and crash-safety analysis.
Electrical & Electronics — structural dependability, drop simulations, and thermal management.
Multi-physics simulation result
Projects

FEA & CAE Projects

OIL & GASFitness-for-Service Assessment of a Pipeline During Lifting Operations
Duration · 6 Months

Fitness-for-Service Assessment of a Pipeline During Lifting Operations

Fitness-for-Service assessment of a live pipeline affected by Corrosion Under Pipe Support (CUPS), validating structural integrity during a 50 mm lift for UT inspection. Reusable lifting guidelines were developed defining safe criteria for multiple pipe sizes and configurations.

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OIL & GASPipe Stress Analysis of a 44-inch Incinerator Line
Duration · 6 Weeks

Pipe Stress Analysis of a 44-inch Incinerator Line

Static and dynamic pipe stress analysis validating a proposed incinerator piping design modification, enabling the customer to approve and proceed with site modifications while improving incinerator efficiency and minimising the risk of future operational failures.

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RENEWABLE ENERGYFEA of a Wind Turbine Generator (WTG) Transformer
Duration · 5 Weeks

FEA of a Wind Turbine Generator (WTG) Transformer

FEA-based structural validation of a WTG transformer under transportation, lifting and extreme-wind acceleration loads. Critical stress regions were identified and the lifting arrangement, tie-down configuration and weld design were optimised for a manufacturing-ready design.

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NUCLEARSeismic Qualification of a 3.2 MW Induction Motor for a CCW Pump
Duration · 5 Weeks

Seismic Qualification of a 3.2 MW Induction Motor for a CCW Pump

Equipment qualification for Operating Basis Earthquake (OBE) loading, giving the customer the confidence to release the motor for manufacturing and supply it to a nuclear power plant site — a decision that could not be made without seismic qualification proof.

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WATERPipe Stress Analysis of a 40 MLD Desalination Plant
Duration · 6 Months

Pipe Stress Analysis of a 40 MLD Desalination Plant

Pipe stress analysis of critical piping systems under operating and environmental loads for a 40 MLD desalination plant, ensuring piping integrity, safety and code compliance to support safe and reliable plant execution.

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FAQ's

FEA & CAE Simulation FAQs

ProSIM provides a comprehensive suite of computer-aided engineering (CAE) and multi-physics simulation services designed to turn intricate data into practical business insights. Our core offerings include linear and non-linear analysis, dynamic and frequency domain analysis, design optimization, structural integrity assessments, and coupled multi-physics modeling. We act as your dedicated engineering advisors to help you solve complex design challenges, improve product reliability, and accelerate time-to-market.

We offer highly adaptable partnership structures tailored to fit your specific operational and budgetary needs. You can choose from Offshore CAE Services managed through our dedicated Bangalore delivery center, Onsite CAE Consulting where we deploy resident engineers directly to your facility, or Dedicated CAE Outsourcing via Master Service Agreements (MSAs) to guarantee steady, long-term engineering bandwidth for continuous project demands.

Risk mitigation and regulatory compliance are at the forefront of our engineering process. Our experts meticulously evaluate and validate your designs to guarantee they satisfy rigorous, sector-specific global safety codes. We possess deep expertise in qualifying products against leading international standards, including ASME B&PV, API, EN / ISO, IEEE, and DNVGL.

By leveraging advanced simulation data, our team streamlines your products through parametric, topology, shape, and sizing refinements. This optimization process eliminates unnecessary weight and material waste while maximizing stiffness, strength, and overall performance, ultimately driving down manufacturing costs and enhancing product margins.

Yes. When a breakdown occurs, our dedicated consulting team conducts comprehensive failure analysis to identify the exact root causes of the structural or mechanical failure. Beyond just identifying the problem, we provide actionable, corrective design modifications to ensure the issue is resolved and long-term durability is restored.

Absolutely. For capital-intensive industries, we conduct rigorous asset longevity evaluations, including Remaining Life Assessment and Extension (RLA/RLE) and Fitness-for-Service (FFS) analyses. By predicting long-term durability and evaluating potential fatigue life, we help plant managers and operations executives safely extend the lifespan of critical components and systems.

Our Bangalore-based delivery center operates as a highly scalable, dependable, and cost-effective hub for complete simulation lifecycles. By outsourcing your finite element workflows to us, you gain access to top-tier engineering talent managing everything from detailed pre-processing, geometric cleanup, and rigorous quality assurance to solver execution and actionable post-processing insights — all seamlessly integrated into your global supply chain.

Yes. Through our onsite placement program, we can seamlessly integrate highly trained ProSIM professionals — such as application engineers or resident consultants — directly into your workspace. Our personnel are rigorously cross-trained in specific domains and can manage specialized FEA/CAE solvers (like ANSYS, Radioss, and OptiStruct) and CAD tools locally, engaging face-to-face with your team and clientele.

Our comprehensive simulation offerings are backed by deep, sector-specific knowledge supporting high-stakes global industries. We routinely partner with executives and engineering teams in the Energy sector (nuclear, wind, offshore, oil & gas, thermal), Aerospace & Defence (impact tests, weight minimization), Automotive (NVH, crash safety, durability), and Electrical & Electronics (thermal management, drop simulations).

To ensure seamless integration with your existing engineering workflows, our professionals rely on a powerful combination of leading commercial platforms and versatile open-source programs. Our deep technical proficiency covers ANSYS, Abaqus, Nastran, OptiStruct, Radioss, and Code_Aster for analysis, alongside AutoCAD, CATIA, Solidworks, and Hypermesh for geometric cleanup and precise model configuration.

Blog

Insights from Our Simulation Desk

Technical explainers and case notes on non-linear FEA, design optimization, seismic simulation, remaining-life assessment, meshing and coupled multi-physics.

Linear Static Isn't Enough: When to Go Non-Linear

Linear Static Isn't Enough: When to Go Non-Linear

The signals — large deflections, contact, plasticity — that mean a linear model is no longer telling the truth.

  • Geometric non-linearity
  • Contact mechanics
  • Material plasticity
Topology vs. Shape vs. Sizing Optimization

Topology vs. Shape vs. Sizing Optimization

Which design-optimization method to reach for, and how they combine to cut weight without losing stiffness.

  • Parametric studies
  • Topology optimization
  • Sizing refinement
Response Spectra & Time-History: Seismic FEA Explained

Response Spectra & Time-History: Seismic FEA Explained

Frequency- and time-domain routes to seismic qualification and when each is required by code.

  • Modal analysis
  • Response spectrum
  • Time-history
Fitness-for-Service & Remaining Life with FEA

Fitness-for-Service & Remaining Life with FEA

Using creep, fatigue and fracture models to justify safe life extension of ageing assets.

  • RLA / RLE
  • Creep-fatigue
  • Fracture assessment
Meshing for Accuracy: Density, Element Size & QA

Meshing for Accuracy: Density, Element Size & QA

How mesh quality metrics and convergence studies keep results defensible.

  • Mesh convergence
  • Element quality
  • QA workflow
Coupled Multi-Physics: Thermo-Mechanical & FSI

Coupled Multi-Physics: Thermo-Mechanical & FSI

Modelling the interaction between fluids, temperature and structure in a single solution.

  • Fluid-structure interaction
  • Thermo-mechanical
  • Co-simulation