FINITE ELEMENT ANALYSIS

FEA & Structural Simulation for Real Hardware

Validate strength, stiffness, vibration behaviour and structural risk before committing to fabrication or tooling. YantriX combines finite element analysis with mechanical CAD redesign and physical product development.

Discuss Your FEA RequirementView FEA Case Study
  • ANSYS Mechanical
  • SolidWorks Simulation
  • CAD-to-simulation
  • Design iteration
  • NDA available

Engineering simulation for real hardware

CAD → FEA → Engineering decision → CAD redesign → Prototype / iteration

Simulation results are interpreted against the defined assumptions and used to guide practical mechanical design changes.

Simulation scope

FEA Capabilities

Structural studies are scoped around the component, load case, and engineering decision required.

01

Structural

  • Static structural analysis
  • Stress and deformation
  • Load-path evaluation
  • Stiffness assessment
  • Geometry and thickness iteration

02

Dynamics

  • Modal analysis
  • Natural-frequency assessment
  • Vibration-focused structural evaluation

03

Optimization

  • Topology optimization
  • Weight reduction studies
  • Geometry reinforcement
  • Stiffness-to-weight iteration

04

Thermal / structural

  • Thermal loading where relevant
  • Thermally induced structural effects when in scope
Engineering evidence

FEA case studies from defined studies

These engineering studies use the project assumptions and simulation results recorded for each case. Numerical values below are identified as simulation results or inputs.

Finite element analysis stress distribution on solar mounting structure

ENGINEERING STUDY · Simulation · Structural FEA & Optimization

FEA Simulation & Structural Optimization for Industrial Mounting Assemblies

Structural engineering study evaluating stress concentrations, deflection, and material optimization on heavy-duty industrial mounting brackets using finite element analysis.

Problem

  • The industrial mounting bracket study focused on stress concentrations near transition corners and bolt holes under defined static load cases. Increasing member thickness uniformly can add material; the study compared localized rib placement and fillet-radius changes as geometry alternatives.

Analysis

  • Imported parametric bracket solid geometry into ANSYS and SolidWorks Simulation environments.
  • Conducted baseline FEA on original geometry, revealing high localized stress (285 MPa) near base bend radii.
  • Refined mesh density locally using adaptive h-refinement at notch radii until stress converged within 3%.
  • Introduced continuous triangular stiffening gussets and increased inner bend radii from 2 mm to 5 mm.

Engineering output

  • Simulated 32% reduction in peak von Mises stress on optimized bracket geometry (285 MPa down to 194 MPa)
  • The simulation predicted a 25% reduction in maximum cantilever tip deflection under identical load conditions
  • The simulation estimated a static factor of safety of 2.4 against the defined material yield strength
  • The simulated geometry comparison favoured targeted gusset reinforcement over uniform sheet-gauge thickening

Deliverables

  • Full FEA simulation summary report with von Mises stress and displacement field plots
  • Mesh-convergence results tables
  • Optimized 3D CAD solid model with reinforced gusset geometry
  • Material sizing and weight comparison breakdown
  • 32%Peak Stress Reduction (Simulation Result)
  • 25%Deflection Reduction (Simulation Result)
  • 2.4×Factor of Safety (Simulation Result)
  • 0Yield Exceedances in Model (Simulation Result)
Read the full case study
Aerial infrastructure inspection drone with onboard perception system

ENGINEERING STUDY · Simulation · Topology Optimization & FEA

Drone Airframe Topology Optimization & Structural Sizing

Airframe engineering study using topology optimization and modal FEA to compare structural mass and predicted vibration behaviour across a CAD design iteration.

Problem

  • Commercial survey drones benefit from low airframe mass, while structural stiffness and modal behaviour remain design considerations. This study investigated topology optimization and modal frequency analysis as inputs to a lightweight airframe CAD iteration.

Analysis

  • Defined structural design domains in ANSYS Mechanical, preserving motor mounts and avionics plate interfaces.
  • Executed density-based topology optimization under combined thrust and landing reaction forces.
  • Interpreted organic density isosurfaces and remodeled clean parametric CAD geometry in SolidWorks.
  • Conducted modal analysis; the model estimated the first bending mode at 118 Hz.

Engineering output

  • Simulated airframe mass reduction from 410 g down to 320 g (22% mass savings in CAD model)
  • The simulation estimated a 118 Hz first natural frequency against the 110 Hz motor-excitation threshold
  • The simulation estimated a structural factor of safety of 2.4 for the defined 3G landing case
  • Produced manufacturable hybrid airframe assembly combining 2D CNC carbon plate and 3D printed brackets

Deliverables

  • Topology optimization density progression data and analysis report
  • Modal frequency response report with animated mode shape plots
  • Parametric SolidWorks 3D CAD files of the lightweight airframe
  • Composite fabrication and hardware assembly guidelines
  • 22%Mass Reduction in CAD (Simulation Result)
  • 118 HzFirst Natural Frequency (Simulation Result)
  • 2.4×Landing Factor of Safety (Simulation Result)
  • PETG-CFComposite Material (Material Specification)
Read the full case study
Simulation you can defend

A clear path from load case to CAD iteration.

A colourful stress plot is not engineering validation. Useful FEA depends on realistic loads, material assumptions, boundary conditions, mesh quality, convergence, and interpretation.

  1. 01

    Engineering question

    Define the stress, deformation, stiffness, frequency, safety margin, or design comparison to evaluate.

  2. 02

    Geometry preparation

    Simplify non-structural detail while retaining features that carry load or define interfaces.

  3. 03

    Material definition

    Set material properties for the component and its intended manufacturing process.

  4. 04

    Loads and constraints

    Represent supports, forces, interfaces, and operating loads from the available requirements.

  5. 05

    Mesh strategy

    Refine holes, fillets, interfaces, load paths, and regions with steep stress gradients.

  6. 06

    Convergence

    Compare important quantities across mesh refinement where required by the study.

  7. 07

    Engineering checks

    Use reaction-force checks, hand calculations, or engineering sanity checks where appropriate.

  8. 08

    Design iteration

    Translate findings into CAD changes and rerun the analysis when included in scope.

  9. 09

    Physical correlation

    Compare predictions with prototype or measured results when project scope includes testing.

What we need to start

Share the inputs you have.

  • 3D CAD or geometry
  • Material and manufacturing process
  • Expected loads and supports
  • Operating environment
  • Design limits and target performance
  • Known failure point, if applicable

Early-stage CAD is acceptable when study assumptions can be defined clearly. NDA coordination is available before confidential data exchange.

Scoped deliverables

A report tied to the question.

  • Simulation setup summary, assumptions, and load cases
  • Stress and deformation plots, with modal results where applicable
  • Mesh-refinement or convergence information where required
  • Critical-region identification, CAD feedback, and design recommendations
  • Revised CAD and technical report when included in scope

Deliverables, mesh detail, and CAD revisions are agreed for each project scope.

Applications

Engineering questions in product context.

Industrial machinery

Brackets, frames, machine structures, mounting systems, and load-bearing assemblies.

Robotics

Arm links, actuator mounts, robot chassis, and vibration-sensitive structures.

UAV / lightweight systems

Airframe stiffness, modal behaviour, and structural weight studies.

Product hardware

Housings, supports, structural components, and mechanical assemblies.

Also evaluating heat transfer or fluid behaviour? Explore CFD & Thermal Simulation →
Frequently asked questions

Before you scope a study.

A few practical details about starting a simulation engagement.

What do you need to start an FEA project?

A 3D CAD model, material, expected loads, support or mounting conditions, operating environment, design limits, and the question you need answered are useful starting points. Early CAD is acceptable when assumptions can be defined clearly.

Can you work from an early concept model?

Yes. An early-stage model can support an initial study when we can agree on the assumptions, load cases, and performance target. Simulation predictions should be interpreted within those defined conditions.

Start a technical discussion

Have a structural question?

Share your CAD, operating assumptions, and the engineering decision you need to make. We’ll review the scope and discuss an appropriate next step.

Discuss Your FEA RequirementAll engineering services