Garbage In, Garbage Out.... The Importance of Accurate FEA Inputs

Finite Element Analysis (FEA) is a powerful tool, but like any tool, its results are only as good as the data we feed it.
One of the biggest pitfalls in simulation is relying on inaccurate inputs—because even the most advanced analysis won’t save a design built on bad assumptions.

When setting up an FEA, we focus on:
1. Loads & Constraints: Are we applying forces, pressures, and boundary conditions that truly represent real-world use? Over-simplifying can lead to misleading results.
2. Material Properties: Using the right material data (not just default values) is critical. Yield strength, fatigue limits, and real-world variability all matter.
3. Mesh Quality: A coarse mesh might solve fast, but it can miss critical stress concentrations. On the flip side, over-refining can waste time without adding accuracy.
4. Contact & Connections: How parts interact—bolted, welded, or press-fit—can drastically affect stress distribution. Ignoring this can lead to false conclusions.
That’s why we always cross-check our FEA results with physical testing and real-world feedback. Simulation is a guide, but reality is the ultimate test.