What is the Assembly simulation solution?

It’s a digital tool that allows automotive manufacturers to virtually try-out their real-world assembly processes—from part positioning and clamping to spot welding and release sequences.

Why should manufacturers use assembly simulation?

By modeling the entire process virtually, manufacturers can test strategies, identify issues early, and optimize workflows. This reduces costly trial-and-error on the shop floor and ensures smoother production.

How does the solution support quality control?

The solution enables detailed virtual checks for dimensional accuracy, gaps, distortions, and welding stresses. Users can also simulate weld forces, pressures, and robot operations to predict distortions before physical trials.

Can the solution emulate real shop-floor operations?

Yes. It mirrors actual workflows step by step, including jig creation, welding parameters, and robot assignments. Multiple robots can be deployed in parallel, just as in real production.

What industries benefit most from this solution?

Automotive and other manufacturing industries that rely on resistance spot welding gain the most value, as they can refine complex assembly processes virtually before committing to physical production.

How does the solution improve efficiency and reduce costs?

By allowing experimentation in a fully digital environment, manufacturers can optimize sequences, avoid errors, and validate processes upfront—saving time, reducing rework, and improving product quality.

Assembly

A powerful simulation tool for testing and optimizing real-world assembly processes in a fully digital environment.

Why Use Assembly Simulation

Assembly simulation software empowers automotive manufacturers to explore and refine their processes virtually, long before physical trials. By modeling every step—from part positioning to clamping and welding—it enables experimentation with alternative strategies, early identification of potential issues, and optimization of the sequence for greater efficiency. This proactive approach minimizes costly trial-and-error on the shop floor, streamlines production readiness, and drives smarter, more reliable assembly outcomes.

What You Get

Our solution helps you to optimize and test your assembly processes.

A Complete Virtual Assembly

A digital version of real-world assembly processes, from positioning and clamping to spot welding and release sequences.

Seamless Ecosystem Integration

Built to work smoothly with CAD, PLM, Excel, and existing digital workflows without disrupting established practices.

Realistic Parts Early

Generate distortion-aware parts automatically, so engineers can work with realistic geometry from the very beginning.

Continuous Data Evolution

Easily update processes as new CAD, simulation, or scanned part data becomes available—no need to restart setups.

Industry-Proven Solution

Shaped together with OEMs to reflect real-world challenges, best practices, and proven methods.

Efficiency and Cost Savings

Reduce rework, fixture adjustments, and trial-and-error by validating quality upfront and accelerating production readiness.

Key Features

Intuitive Workflow

Easy-to-use, visual interface—no FE or meshing expertise needed.

High Predictability

Accurate distortion prediction with a robust multiphysics solver and scalable performance.

Pre-Configured Templates

Ready-made automotive sub-assembly templates (A/B-pillars, body sides, closures) plus easy custom process creation.

Flexible Process Design

Drag-and-drop customization for fast, intuitive setup.

Integrated Tooling Design

Create clamps, locators, guides, and supports in-app—no external CAD required.

Flexible Data Inputs

Use CAD, simulated, or scanned part data—fully associative for automatic updates.

In Action

Discover how companies use Assembly simulation software to solve complex engineering challenges.

Distortion and Dimensional Accuracy Prediction

Small deviations in single component cause gaps and shifts after welding. Assembly simulation predicts distortions early, optimizes clamping and weld strategies, and keeps geometry within tolerance—reducing fixture rework and delays.
Positioning, Clamping and Welding Sequence

Positioning, clamping, and welding order strongly affect assembly accuracy. Assembly simulation lets engineers optimize these sequences virtually, reducing trial-and-error and ensuring stable, in-tolerance results.
Virtual Try-Out and Early Validation

Late BiW validation makes changes costly and risky. Assembly simulation enables early process validation with CAD, stamping, or scan data, resolving issues before tooling—saving time and avoiding SOP delays.

Resources to Get You Started

Introducing Keysight’s Novel Assembly Simulation Software: The New Standard for Automotive Body-In-White Assembly Distortion Engineering

View Blog

Webinar

Future of Automotive Assembly

Webinar

Future of Automotive Assembly - Global Introduction and Assembly Challenges

Blog

Virtual Process Chains: Building Digital Workflows for Smarter Joining & Assembly in Automotive BIW

Have Questions? We've Got Answers

Ready to change your product design and testing to virtual?

Let’s discuss how our simulation tools can support your next project.

Request Information

What are you looking for?

I'm looking for support Pro Oscilloscopes Handheld Spectrum Analyzers Compact Signal Generators Find a solution Get technical support Take a class Find us at events Premium used equipment KeysightCare Buy online

No product matches found - System Exception