Bentley and ESI Group work together to refine the Flying Spur through a sustainable design process

12 May 2021
Paris, France

ESI Group, a global player in virtual prototyping for industries, worked hand in hand with Bentley on the optimization of one of the world’s finest four door sedans, the Flying Spur. Thanks to virtual prototyping, teams have been able to eliminate noise, vibration and harshness (NVH) and reduce physical parts in the test phase.

Illustration from Bentley

Illustration from Bentley

Advanced virtual design processes have been used in the testing and production cycles of the third Flying Spur generation. Thanks to ESI’s virtual prototyping, a weight optimization program for the Flying Spur could be undertaken on 40 different components. The finely tuned process enabled acoustic tests for any airborne sounds filtering into the cabin to be completed, as well as any impact from the structure itself, such as tire noise. This ensured the correct soundproofing materials were deployed in the right locations around the vehicle, so passengers can enjoy the quietest cabin experience possible. These cutting-edge techniques are ultimately more sustainable, dramatically reducing the need to manufacture physical parts.

By using Virtual Prototyping, Bentley succeeded in what we set out to do –optimize every component of the Flying Spur firstly in the virtual world before we create physical parts. At the same time, we have reduced physical prototypes, creating the quietest in-cabin experience for our customers. Virtual Prototyping means fewer prototypes have to be built, and we reduce our testing mileage. It also helps influence the design and engineering of the car at an early stage and affords significant benefits in the extensive testing phase.

Simon Noble
Acoustic Engineer at Bentley Motors

ESI Group used their expertise in the challenging job of pinpointing unwanted cabin noise, relying on Virtual Prototyping, allowing Flying Spur designers to use digital mock-ups that helped identify NVH before building a physical version of the car. The virtual prototyping helped to reduce physical parts in the test phase and save time during the process. ESI Group’s ambition is to boost human creativity to drive industrial performance to ever higher levels. We are proud to collaborate with Bentley on one of the best luxury sedans in the world!

Jonas Fredriksson
Managing Director ESI Northern Europe