Digital Twin Simulation

The aim of the "digital twin" is to develop a realistic computer image in order to make the generation & interpretation of the component design more comprehensive and efficient.

Forged motorbike piston for racing
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Digital copy of your assembly for simulation and optimization

The final product or concept is realized as a digital twin on the computer, where design development and idea generation can also be considered. The virtual product is designed according to the customer's specifications in a wide range of simulations (FEM, MKS, CFD), bionic biomimically or numerically optimized and validated.

The digital twin enables an efficient development cycle, as all bench tests are run virtually at an early stage. The test palette ranges from thermal and mechanical load tests to verification of the product's flow or heat transfer behavior. In addition, influences from the manufacturing process (residual stresses, anisotropies, etc.) or influences from electrification are also taken into account as a whole in the evaluation of the products in a development cycle.

SinusPro has the expertise to build simulation models that are close to reality. For example, welds, bolts, forged, cast, laminated or 3D-printed components can be realistically simulated and mapped on the computer with the manufacturing and material properties. 3D printed components realistically simulated and mapped with the manufacturing and material properties on the computer.

For the creation of the digital twin, SinusPro has been using state-of-the-art CAE software solutions for thermal, mechanical and fluid simulation models for many years, in addition to software developed in-house. softwareFor many years, state-of-the-art CAE software solutions have been used for thermal, mechanical and fluid simulation models.


As a customer, you can rely on over 20 years of experience in CAE services and the associated development of simulation software. Numerous real products have already been translated into functional digital twins for a wide range of industrial sectors and subsequently evaluated and optimized. Did you know that we have expert status? Based on our calculations and simulations, we provide independent expert opinions in the fields of strength and functional performance of assemblies.

Your contact

Dominik Fleischhacker

Dominik Fleischhacker

Dipl.-Ing. (FH), B. Sc. (WU)

Head of Analysis and Research

Our services in the field of simulation

Process Simulations

Simulations can be used to virtually run through a wide variety of manufacturing processes in order to determine whether the selected process parameters are optimal for the component.

The portfolio includes casting, injection molding, forging, welding and additive manufacturing simulations, for example to investigate and optimize residual stresses, warpage or basic feasibility. This means that the manufacture of components can also be examined at an early stage and fed back into product development.

Design of Assemblies

Due to the integration of functions and the increasing demands on products, the range of different tests is growing. Simulation serves as a solution for this. By using a single virtual prototype, it is possible to verify a wide variety of requirements and to take these into account in design development from the outset.

SinusPro's services in this field include static, thermal and dynamic simulations, such as crash & burst simulations, as well as fatigue evaluations & CFD flow simulations.

Optimization of Assemblies

Existing components or new concepts can be optimized with respect to the defined objectives using a wide variety of numerical methods. Mechanical properties (stiffness, strength, heat transfer, vibration behavior) can thus be massively improved in a short time.

A technical component can also be optimized with regard to its production. It can be specially adapted to the manufacturing process and thus the feasibility, price and production times can be adjusted.

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Your advantages with the Digital Twin

Mapping of the entire development process

Virtual development enables the integration and, above all, the linkage

of all development steps - from design development by means of optimization

through design to process simulation.

Reduction of development times & costs

Virtual development enables the consideration of all test bench tests and

process parameters already at the beginning of the design generation. We only need one virtual test specimen for all tests.

Efficient & individually tailored to your needs

Virtual development allows us to automatically validate & evaluate the adaptation of the design - precisely tailored to the wishes of our customers.

News from the simulation area

Fracture Behavior Of Water Tank
The fracture behavior of plastic water tanks is determined by means of simulation.
compressor bracket
Weight Optimization for Audi
Weight optimization of a compressor holder, a German automotive OEM.