About the Client

A Tier-1 automotive interior systems supplier based in Europe, supporting global OEMs. The client required virtual validation of a new instrument panel (IP) design to meet global regulatory standards before tooling release.

The Challenge

The client was working under a tight schedule and needed to complete virtual validation before committing to tooling. The validation scope included compliance with FMVSS, ECE, and OEM-specific requirements. The challenge also involved managing rapidly evolving CAD maturity levels while ensuring accurate and timely analysis delivery.

Key challenges included:

• Compressed timeline between CAD freeze and tooling kick-off
• Need for multiple types of simulations across functional domains
• Limited availability of validated material properties for analysis
• Coordination across design, analysis, and regulatory compliance teams

The Solution

We executed a complete virtual validation workflow aligned with international regulations and the client’s internal development milestones.

Key solution components included:

• Prioritization of CAD maturity stages for meshing activities
• Creation of high-fidelity finite element (FE) models
• Execution of the following simulations:
  • Static stiffness
  • Quality feel evaluation
  • Head impact compliance
  • Modal and thermal performance
  • Passenger Air Bag (PAB) deployment load checks
• Support in sourcing validated material cards by coordinating with authorized testing labs
• Compliance review and documentation aligned with ECE and FMVSS standards

The Impact

The virtual validation program enabled the client to move confidently into tooling with a high level of design confidence and regulatory alignment:

• On-time validation delivery supporting critical launch timelines
• Full coverage of regulatory simulations without the need for physical rework
• Minimized risk and retooling costs through preemptive validation
• Improved model accuracy via sourcing of validated material data
• Strengthened OEM readiness with comprehensive compliance documentation