Simulation engineering helps firms cut environmental impact

A report released by Ansys and McKinsey & Company articulates the role of simulation engineering as a tool for fostering innovation while adhering to sustainability regulations.

The report explores how simulation engineering enables organisations to model, test, and optimise products and processes within virtual environments. This approach allows companies to reduce material use, energy consumption, and emissions prior to creating physical prototypes. According to the findings, businesses using Ansys simulation solutions experienced a reduction in direct, indirect, and downstream GHG emissions across a product's lifecycle by at least 10%.

Simulation technology's transformative potential is highlighted across various stages of a product's lifecycle. It aids in optimising design, minimising manufacturing waste, and supporting energy-efficient operations, offering insights with direct environmental impact.

The report presents a structured four-step framework for businesses to exploit simulation effectively. This includes prioritising key sustainability metrics, assessing simulation's impact on environmental and economic facets, quantifying results into measurable outcomes like CO2 reductions, and integrating findings to inform strategic decisions company-wide.

In one of the report's case studies, Infineon Technologies used simulation to optimise the design of electric vehicle inverters, cutting energy losses by 50%. This led to a 2-3% reduction in the lifecycle emissions of electric vehicles. This case underscores the downstream impact of efficient design achieved through simulation.

Another example presented is Danfoss Drives, which utilised simulation to develop a new drive platform, achieving up to a 45% reduction in use-phase emissions compared to previous models. This achievement was more than double the emission reductions predicted without simulation's use, emphasising its value in environmental improvement efforts.

Mars, a renowned food provider, employed simulation to rework its packaging designs, reducing development time by 40% and substantially decreasing plastic use across its packaging types. This initiative not only reduced waste but also expedited the introduction of sustainable solutions.

These case studies highlight the critical role of simulation in enhancing sustainability initiatives across industries. They demonstrate how simulation drives innovation and supports improved environmental outcomes.

Despite these documented benefits, the report underscores a missed opportunity as simulation remains underutilised in many sustainability initiatives. It recommends investing in expertise and fostering collaboration between sustainability and engineering teams to fully capitalise on simulation's potential.

Adding to this perspective, Prith Banerjee, CTO of Ansys, stated, "Simulation is essential for driving sustainable innovation. It empowers companies to meet ambitious environmental goals while accelerating the pace of progress."