Digital Mockup (DMU) is the virtual assembly of all product components in a CAD environment to validate geometric fit, clearance margins, and packaging constraints — replacing physical prototype builds as the primary medium for assembly interference detection. EMUG Tech delivers six DMU and clearance check service areas: automated clash and hard interference detection across all component pairs; minimum clearance analysis with configurable thresholds per interface type; kinematic motion and dynamic clearance envelope computation; engineering change impact DMU triggered by PLM change releases; multi-CAD and supplier data DMU across NX, CATIA, Creo, and STEP formats; and automated DMU report generation with PLM issue creation. All programmes follow the EMUG CLEAR Framework.

EMUG CLEAR is the five-phase DMU automation delivery methodology: Capture — DMU workflow analysis, clearance requirement definition, and component pair inventory; Layout — tool architecture design, clearance threshold matrix, and PLM integration specification; Engineer — DMU tool development, kinematic definition, and report template build; Assess — integration testing on production assembly data with UAT; Release — deployment, milestone scheduling, and engineering team training. CLEAR addresses the most common DMU automation failure: tools that detect clashes but produce unstructured output that engineers cannot efficiently act on — CLEAR designs the clash classification, severity ranking, and PLM integration that makes findings actionable.

EMUG Tech delivers DMU automation across the major CAD and visualisation platforms used in complex product programmes: Siemens NX Assembly with NX Open API for NX-native DMU and clearance analysis; Teamcenter Vis (JT-based visualisation) for large assembly DMU across multi-CAD product structures; CATIA V5 DMU Navigator and DMU Space Analysis with CAA scripting for CATIA programme environments; 3DEXPERIENCE SIMULIA and CATIA DMU for V6 environments; PTC Creo Assembly for Creo-native clearance checking; and JT-format neutral assembly DMU for programmes mixing NX, CATIA, Creo, and supplier STEP data. Platform selection depends on the programme’s primary CAD environment and PLM system.

EMUG CLEAR implements clearance threshold matrices that define minimum clearance values per interface type rather than applying a single value across the entire assembly. The threshold matrix is defined in the Capture phase from design requirements and engineering standards: structural static interfaces (minimum clearance from DRD or engineering specification); thermal expansion interfaces (clearance accounting for differential thermal growth at operating temperature range); assembly variation interfaces (clearance accounting for GD&T tolerance stack-up at worst-case condition); and functional motion clearance (clearance envelope across full mechanism travel range). Safety-critical interfaces — fuel, hydraulic, electrical, and brake system clearances — are given separate threshold values and escalation priority classification.

Kinematic motion clearance checking simulates the motion of mechanisms through their full travel range — doors, bonnets, hoods, seat adjusters, suspension travel, landing gear extension, control surface deflection — and computes the clearance between moving and static components at every position in the motion envelope. EMUG CLEAR builds kinematic motion definitions in NX Motion, CATIA Kinematics, or 3DEXPERIENCE, then automatically sweeps the mechanism through its travel range and records the minimum clearance between every moving-static component pair at each position. The output identifies the position and component pair where minimum clearance occurs — the design-critical condition that requires engineering attention.

EMUG CLEAR stores DMU results in the PLM system and creates structured issues for each clash finding: in Teamcenter, DMU results are stored as simulation objects linked to the assembly item revision, and clash findings create Teamcenter issue or change request objects with component pair reference, clearance measurement, and screenshot attachment; in Windchill, clash findings create Windchill problem reports linked to the affected parts; in 3DEXPERIENCE, findings create issue objects in the ENOVIA ENOVIAvpm structure. Issue assignment to the responsible design team is automated from the PLM component ownership data — the engineer responsible for the clashing component receives the issue automatically without manual routing.

A focused static clash and clearance automation tool for a single assembly level — for example, automated full-vehicle exterior package DMU in JT format with severity-ranked report and PLM issue creation — typically delivers from Capture to Release in 8 to 14 weeks. A multi-capability DMU programme covering static clash detection, kinematic motion clearance, change-triggered delta-DMU, and automated reporting typically takes 14 to 24 weeks. Performance on large assemblies (100,000 to 1,000,000+ components) is validated in the Assess phase — large assembly performance optimisation is common and typically adds 2 to 4 weeks to the programme.

Assembly DMU and clearance check automation programmes are delivered across automotive OEMs and Tier 1 suppliers, aerospace and defense manufacturers, industrial machinery producers, energy companies, and high-tech electronics firms 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. DMU automation delivery from Hyderabad, Germany, and Dubai with on-site requirements capture and tool deployment capability at client engineering facilities globally.