The automotive industry is shifting from traditional physical testing to simulation-driven development, where the concept of “near-zero prototypes” aims to minimize physical prototypes to only final validation stages. This transition is enabled by the evolution of computer-aided engineering (CAE), which now integrates multi-domain simulations such as structural, thermal, fluid, and system-level analyses early in the design phase.
Modern development processes combine CAE with simulation process and data management (SPDM), multidisciplinary design optimization (MDO), and AI-driven modeling to support fully virtual product development. These approaches allow companies to compress development cycles, integrate real-world data, and improve collaboration across teams and suppliers.
Another important aspect is the integration of engineering workflows with broader business objectives through structured data management and traceable processes. At the same time, establishing confidence in simulation results through validation frameworks and data-driven assessment plays a critical role in reducing reliance on physical testing.
The ESTECO blog by Mario Felice, explains that achieving near-zero prototypes requires a cultural and technological shift, where simulation becomes central to decision-making, supported by integrated platforms, automation, and enterprise-wide data systems.
Image courtesy: ESTECO