Virtual modelling.
Digital design and manufacture · Technical principles
Revision notes
Simulation
A CAD/CAM simulation is a virtual run-through of a manufacturing process that allows designers to evaluate feasibility before production.
Advantages
Identifies collisions, tool clashes, and axis limit errors
Predicts machining time and production efficiency
Enables nesting to reduce material waste
Assesses 3D print quality and support material requirements
Virtual modelling (A-level only)
Virtual modelling uses 3D CAD and simulation software to test product performance before manufacture.
Checks fit, clearance, and movement of components
Simulates CAM processes to prevent machining errors
Allows production system planning involving FMS cells, conveyors, robots, and AGVs
Computational fluid dynamics (CFD)
CFD is a 3D simulation tool used to analyse fluid and gas flow around products.
Used to assess aerodynamic performance (e.g. vehicle drag)
Results inform design improvements
Reduces reliance on physical testing such as wind tunnels
Finite element analysis (FEA)
FEA analyses stress and strain within CAD models.
Simulates forces, vibration, and shock loading
Highlights weak points using colour-coded stress maps
Enables optimisation through repeated testing
Used for both static and dynamic testing of products
Think you have got this topic?
Test yourself before moving on, or use flashcards for a quick recall session.