EMUG Tech delivers six CAE automation and data integrity service areas: FEA pre-processing automation reducing model setup time for ANSYS, Abaqus, Nastran, and HyperMesh; mesh quality enforcement tools running standard checks before every solver submission; HPC batch submission and job management automation; post-processing and results extraction automation generating standard plots and reports; CAE data integrity tools linking simulation models and results to originating CAD geometry revisions; and automated report generation from simulation results databases. All programmes follow the EMUG SOLVE Framework — five phases covering Survey, Outline, Launch, Validate, and Enable.

EMUG SOLVE is the five-phase CAE automation delivery methodology: Survey — simulation workflow observation, effort quantification, and data integrity risk mapping; Outline — tool design, API selection, and data integrity framework architecture; Launch — CAE script and application development with unit testing; Validate — integration testing on production-representative simulation models with UAT; Enable — deployment to engineering workstations and HPC, user training, and 30-day adoption monitoring. SOLVE ensures CAE automation tools are tested against real industrial simulation models before deployment and delivers measurable effort reduction benchmarked against the pre-automation time baseline.

EMUG Tech develops CAE automation using the native scripting interface of each solver and pre/post-processor: PyANSYS (Python API covering ANSYS Mechanical, Fluent, CFX, and ANSYS ACT extensions); Abaqus Python scripting API for model creation, modification, and results extraction in Abaqus/CAE and Abaqus/Viewer; Simcenter Nastran DMAP (Direct Matrix Abstraction Program) and Python for Nastran pre/post automation; HyperMesh Tcl/Python API for model setup, mesh quality checking, and results processing in the HyperWorks suite; and LS-DYNA Python keyword processing for model creation and results extraction. Multi-solver automation programmes connecting pre-processing in HyperMesh through ANSYS or Abaqus solving are an EMUG Tech specialty.

CAE data integrity means that every simulation model and its results are traceable to the specific CAD geometry revision they were computed from — and that this linkage is stored in a governed system rather than in a simulation engineer’s personal folder structure. CAE data integrity is critical for three reasons: design verification evidence for AS9100 and IATF 16949 requires simulation results to be linked to specific design revisions; engineering change management requires knowing which simulations need to be re-run when geometry changes; and design decision making requires confidence that the simulation results referenced in a design review correspond to the current geometry, not an earlier revision. EMUG SOLVE data integrity frameworks implement CAE-to-PLM linkage storing the PLM item revision identifier in CAE model metadata and results records.

EMUG Tech automates ANSYS Mechanical pre-processing using PyANSYS — Ansys’s Python client library covering ANSYS Mechanical, Fluent, MAPDL, and ANSYS ACT extensions. Pre-processing automation covers: geometry import from CAD (STEP, Parasolid, or direct NX/Creo connection via ANSYS SpaceClaim); material assignment from an engineering materials database (eliminating manual material selection); boundary condition application from standard template libraries (fixed supports, pressure loads, thermal conditions by load case type); mesh size and method specification from component class (thin-shell, solid, contact pair mesh settings); and solver parameter configuration from simulation type (static structural, modal, transient thermal). The result is a consistently set-up model ready for solve rather than one configured from memory by each individual simulation engineer.

EMUG Tech builds HPC batch automation frameworks connecting CAE pre-processing completion to solver submission through the cluster job scheduler — LSF, PBS Pro, SLURM, or SGE depending on the HPC environment. The automation covers: validated model packaging (solver input file, material database, result request definition, restart point configuration); job submission with appropriate resource request (cores, memory, wall time by simulation type); queue status monitoring with email or messaging notification on job completion or failure; failed job classification (convergence failure, resource limit exceeded, licensing queue wait) with appropriate retry or escalation logic; and completed job post-processing trigger activating the results extraction pipeline automatically on solver completion.

EMUG Tech connects CAE automation tools to PLM systems using the PLM’s REST API: Teamcenter Services API and Active Workspace API for Teamcenter environments; Windchill REST Services for PTC Windchill environments; and 3DEXPERIENCE REST APIs for Dassault environments. The CAE-PLM integration covers: reading the CAD item revision and associated simulation specification from PLM to drive automation setup; creating CAE simulation objects in PLM linked to the originating CAD geometry revision; saving simulation results (solver output files, results databases, report documents) to PLM simulation objects; and triggering PLM simulation review workflows when results are available for engineering review. This integration makes the PLM system the system of record for simulation data rather than a network drive.

CAE automation and data integrity programmes are delivered across automotive OEMs and Tier 1 suppliers (crash, NVH, durability, thermal), aerospace and defense manufacturers (structural, aeroelastic, CFD, fatigue), industrial machinery producers (structural, thermal, CFD for equipment), energy companies (pressure vessel, pipeline, CFD for flow equipment), and high-tech electronics firms (thermal management, structural reliability) in 20 countries: Germany, France, UK, Netherlands, Sweden, Italy, Spain, Poland, Czech Republic in Europe; India, Japan, South Korea, China, Malaysia, Thailand in Asia-Pacific; UAE and Saudi Arabia in the Middle East; USA, Canada, Mexico, Brazil in the Americas.