Simulation-Driven Digital Twins

25 April 2023  |  2-5 p.m.  CEST  |  Hanau, GER


Model-based, virtual simulation is an innovation driver in vehicle development. Digital twins also use a model-based approach. However, the two approaches are not of course the same. If both approaches are combined, new potentials can be leveraged. Simulation-driven digital twin refers to the creation of a virtual replica of a physical system or product that is driven by simulations. In other words, the digital twin is not just a static 3D model, but it is connected to a simulation environment that models the behavior of the physical system (in real-time).

This approach enables engineers and designers to not only visualize the product design but also analyze and optimize its performance in a virtual environment before it is built in the physical world. The simulation-driven digital twin can provide insights into how the vehicle system will behave under different conditions and can help identify potential issues early on in the development process. The virtual model can be driven by simulations that mimic real-world scenarios and conditions, such as different driving conditions and environments. This allows designers and engineers to optimize the design of the vehicle for performance, efficiency, and safety, and to identify and address potential issues before the vehicle is built in the physical world. With our simpulse day we would like to show the latest approaches of simulation-driven digital twins, clarify differences between the two approaches, highlight limitations and question what strategic role simulation and digital twins play in the automotive industry.


2:00 p.m.
Introduction - Role and Challenges of Simulation-driven Digital Twins in Product Development
Alexander F. Walser  |  Automotive Solution Center for Simulation e.V.

2:15 p.m.
Building the Bridge Between Real World and the Digital Twin for Testing and Simulation Applications.
Dr. Gunar Gräfe  |  3D Mapping Solutions GmbH

2.40 p.m.
Digital Twin Best Practices with Simulation and AI - From the Factory Floor to the Café
Sebastian Poulheim  |  Altair Engineering GmbH

PM Gruppo, Danecca and Gruppo Cimbali optimize machinery, development, manufacturing and production processes with the help of Digital Twin and AI tools. The attendees will get insight to PM Gruppo's application of an improved Sheet Metal Forming Processes that reacts, thanks to an AI-Powered Digital Twin on varying material properties and varying operating conditions resulting in a >15% scrap reduction. The Smart Digital Twin of Danecca enabled them to disrupt their battery development process resulting in a recent project to achieve a 60% cooling time reduction, a saving of cooling pump on/off cycles that led to a 5 miles range increase for the same cell concept. Gruppo Cimbali drives the sustainable Art of Coffee and could reduce their energy losses, balance peak loads, and develop more efficient operating strategies for their professional coffee machines. Get inspired by how these companies converge AI, Simulation and computing.

3.10 p.m.

Fragility Surfaces for Simulation-driven Digital Twins
Dr. Roland Niemeier, Günther Hasna | Dynardo GmbH / ANSYS Germany GmbH

The usage of Digital Twins will be intensified in the near future to build safe and reliable products and environments, enabling a new cooperation along the value chain. For these Digital Twins the metamodels, derived from simulations and based on Machine Learning /Artificial Intelligence algorithms, will be an important component, presenting information in a compact way, while keeping ideally the IP nondisclosed. The analysis of failures can help to avoid or at least to monitor critical degradations during the lifetime of a product. Failure probabilities in dependence of input parameters, limit levels can be visualized as fragility curves or surfaces. These are essentially metamodels of failure rates. The notion fragility curves originated from the study of earthquakes where the damage was studied in dependence of the strength of the earthquake. This is usually a nonlinear behavior with a transition region from non-failure to (complete) failure. Fragility surfaces can be helpful in the whole product lifecycle from the early phase (layout product / manufacturing) to product services, for example a product approaching failure limits during its lifetime. Including these fragility surfaces into Digital Twins we will be able to create efficient workflows to improve the product quality during its lifetime for a safer and more reliable environment. We will present some case studies with applications in microelectronics and automated driving. For these applications, often the required failure rates are very low. Simulation based calculations of these low failure rates need, at least at first sight, a very high number of simulations. For example, if we have a failure rate of one of a million a plain Monte-Carlo approach would need millions of simulations. This is in the most cases not feasible or efficient. Using methods like Latin Hypercube Sampling reduces that typically by one magnitude, for many cases still too much. Therefore, we need methods that help us to calculate these failure rates accurately with a lower number of simulations, gain insights especially into the transition region from non-failure to failure. The focus for the quality of the simulations has to shift towards these transition regions.

3.40 p.m.
Coffee Break
Networking and Exhibition

4:10 p.m.
Interactive Discussion:
Strategic Role of Simulation and Digital Twins as a Game Changer in the Automotive Industry

5:00 p.m.


  • R&D Engineers
  • Researchers
  • Simulation Managers
  • Business Development Managers 


  • gain stimulating impulses and informative insights into the latest methods, software tools and best practices from the perspective of scientists, software vendors and end users


  • discuss future challenges and solution approaches within an unique expert community


  • network and collaborate with other experts to intesivate business relationships and start new research projects closing methodological gaps


Congress Park Hanau
Schloßplatz 1
63450 Hanau  | Germany
Conference Room 5


simpulse day ticket - 25 April 2023
free of charge but limited (on-site)

optional participation in the automotive CAE Grand Challenge requires a fee based ticket (separate registration via carhs)



automotive CAE Grand Challenge

Our simpulse day is accompanying the automotive CAE Grand challenge, which is organized by our cooperation partner carhs. Joining the automotive CAE Grand Challenge on 05 + 06 July 2022 is optional. A separate fee-based registration is required.
Further information on the automotive CAE Grand Challenge can be found here.

Grand Challenges 2023:

  • ARTIFICIAL INTELLIGENCE, MACHINE LEARNING, BIG DATA: Massive Data Exploration of Simulation and Test Results
  • BODY STIFFNESS & STRENGTH: Structural Properties of Battery Packs
  • CAE PROCESS & QUALITY ASSURANCE: CAE in Advanced Vehicle Development (pre-CAD)
  • FULL VEHICLE SIMULATION: Virtual Testing of Autonomous Vehicles
  • MODELING ISSUES CRASH ANALYSIS: Modeling Crash Behavior of Battery Packs
  • OCCUPANT SAFETY: Virtual Testing with Dummies und HBMs
  • OPTIMIZATION & ROBUSTNESS: Robust Design – Creating and Verifying Robust Designs


Automotive Solution Center for Simulation e.V.

Dipl.-Ing. Alexander F. Walser
Curiestraße 2 | 70563 Stuttgart | Germany | +49 (0) 711 699659-10 |


Automotive Solution Center for Simulation e.V.  | Curiestraße 2 |  70563 Stuttgart |  Germany
image credits header / background © Adobe Stock (chesky)