Electric Vehicles (EV) are here. OEMs and suppliers alike have set aggressive timelines to electrify their entire fleet. Fuel tanks, engines, and exhaust lines are being replaced with battery packs, electric motors, and power electronics. To keep pace, automotive engineering teams are adopting an increasingly digital mindset and deploying innovative concepts at an unprecedented rate, while continuing to meet or even exceed performance requirements.

While most OEMs have moved away from the traditional trial-and-error methods and managed to reduce the number of physical prototypes necessary to achieve designs that match their requirements, the “Zero Prototype” journey is no easy task. Engineering departments try to mitigate the lack of available experience at hand with digital solutions to control the risks associated with innovation.

Using the most advanced simulation methodology, Virtual Prototyping, some engineering teams are outright replacing physical tests with virtual ones. In doing so, they are speeding up the development process and anticipating potential issues earlier in their development cycle, thereby counterbalancing the risks associated with innovation. From Virtual testing to in-scenario simulation, ESI can accompany you in the design, manufacturing, and testing of your vehicle.

High-Performance Batteries That Go the Distance


Through their commitment to making “Vision Zero” a reality, the automotive industry has made it abundantly clear that there will be no compromise on safety . Concerns rising around batteries include their optimum location inside the vehicle, their integrity for various road conditions, or in the case of a crash, the protection provided by their housing. The challenge for OEMs and their suppliers is to keep up with evolving requirements. The ability to test various circumstances, virtually, is integral in ensuring the successful development of an electric vehicle with a global mindset.


Reach Optimal Passenger Comfort and Energy Consumption


In the wake of flexible, and sometimes revolutionary, interior layouts, interior climate systems have to be rethought to be consistent with cabin configuration and the demand for individualized comfort. Engineering teams face a difficult challenge as they are called on to reinvent the cabin design while maintaining occupant safety & comfort and delivering high-performing vehicles. With virtual interior engineering, test as many layouts and scenarios of your new car concept before design freeze. Gain a global view of the cabin and manage trade-offs, from human comfort, including acoustics, cabin energy consumption, and associated car range, to passenger safety. More

Achieve energy management targets and maximum range without sacrificing comfort, safety, or cost

Today, it is possible to maximize electric vehicle driving range, while simultaneously offering cabin comfort and safety in a holistic, end-to-end engineering approach. Engineers virtually analyze and assess the interaction of all vehicle variables, inside and outside and in real-time, accurately predicting the impact on the passenger comfort. They do this by accounting for passenger characteristics in combination with heating, ventilation, air conditioning, battery, and powertrain plus external environment like roads conditions, traffic, driving style, and weather. With the Hybrid Twin™, aim to empower OEMs to create a truly immersive, individual, and mobile driving experience.  More

Experience, Validate, and Communicate on the Production Process

As design sets the stage for manufacturing and service, engineering teams must recognize the importance of interacting with their proposed products and processes to assure ease of production and assembly. With Virtual Reality, engineering teams experience, validate, and communicate on the assembly requirements, all while considering the human-centric process interactions. Ultimately, this allows them to significantly reduce future assembly risks and increase efficiency, all while ramping up production to meet key product targets. More

Manufacture Lightweight Designs Enabling Long Ranges Without Sacrificing Cost

Lightweight body structures, engines, and drives are crucial to obtaining an optimal EV performance and maximum range. However, when manufacturing car designs with lightweight materials, meeting tolerance requirements and achieving a high final perceived quality are a challenge for OEMs. Additionally, this often leads to significant over-spending in the try-out phase. OEMs must ensure leading craftsmanship and operational performance of manufacturing processes to meet customers’ high demands, minimize risk, and keep costs within specifications. With simulation, you can virtually manage key manufacturing & assembly processes, inspect perceived quality, securing the entire fabrication process. This is the secret to manufacturing attractive, lightweight, flexibly assembled electric vehicles and ultimately providing the highest quality possible. More

Empower Automakers to Engineer and Manufacture Multi-Material Assemblies With Confidence

With the advent of connected, automated, shared, and electrified (CASE) devices, light-weighting and cost savings are strategically pursued top priorities for automakers to achieve greenhouse gas emissions, fuel economy, range targets and affordable products. On the one hand, weight reduction is a must for body and chassis design, shifting the focus towards high strength-to-weight ratio materials in assemblies that combine, for instance, advanced steels with aluminum and composites. In the process, product engineering and manufacturing complexity is growing and the urgency of uniting those two worlds earlier is increasing. On the other hand, they equally share the cost pressure because high investments on the powertrain side inevitably reduce the “what we can afford” on the body and chassis side. Thus, being able to accurately predict the wide range of manufacturing processes and their assemblies is key to minimizing the amount of costly physical prototypes and tryouts.

Learn how to couple the engineering world and the manufacturing.


Sensing, Connecting, and Reporting for a Safer Driving Experience

To reach the highest safety level, autonomous vehicles must have a 360° view, ensuring they make the right decision by interpreting the data from sensors (camera, radar, or lidar). With Virtual Prototyping and physics-based sensor models, you can verify the reliability of the autonomous systems and develop the safest autonomous vehicles while reducing the testing phase's time and cost. 

Connect With Us to Address Your Challenges


Contact Us

Customer Stories