This Design News article outlines how simulation-driven engineering is transforming the automotive industry. Vehicle launches have been increasingly delayed; the article notes that more than 50% of launches since 2020 were held up by software-related issues. In 2023, 23% of all recalls were attributed to software failures, underscoring the widening gap between software complexity and traditional hardware-led verification.
Automakers and suppliers are turning to digital engineering frameworks in which simulation, AI, and digital twins are leveraged early in the design process (“shift left”). This enables engineers to explore millions of virtual design variations before any physical prototype is built. With multiphysics, simulation, and cloud computing, teams are able to iterate rapidly, identify optimal configurations, and catch integration risks much earlier.
The article highlights a case study where a global rubber-components manufacturer used AI-assisted workflows to simulate vibration isolators and hoses. The result: 10 times faster design cycle and significant time savings per variant. In another example, an electric motor system achieved 95% system-level efficiency by simulating multiple physical and software domains virtually.
Key technical enablers include model-based systems engineering (MBSE), virtual sensor models (e.g., LiDAR, radar, cameras), and unified data platforms connecting hardware, software, and electronics. These tools support collaboration across OEMs and suppliers, reduce integration bottlenecks, and prevent costly redesigns.
The article argues that the industry moving toward software-defined vehicles (SDVs) and electrification must embed simulation and AI-driven validation at the core of development. Leveraging virtual testing not only enhances quality and reliability but also enables faster launches, lowers recall risk, and improves cost efficiency.