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CAE & Testing

What we do

Our CAE (Computer-Aided Engineering) & Testing department is dedicated to supporting product development and definition through advanced numerical simulation technologies. Thanks to an integrated set of tools and multidisciplinary expertise, we are able to explore, understand and optimise projects well before their physical realisation, reducing development times, costs and risks. We address complex phenomena such as thermal distributions, vibrations, wear, structural behaviour and even process-related aspects.

The advanced use of analysis techniques allows us to assess and optimise product performance by acting on geometries, materials and design variants to identify the best solution. We operate across all disciplines of engineering simulation, supporting the project from the conceptual study to the development of complete systems, turning simulation into innovation.

Testing is not just about running trials, but above all about designing the test itself: a strategic process that defines what to measure, how to do it and with which instruments. We handle the definition of test systems and qualification procedures in accordance with regulations, industry standards and internally developed procedures.

The testing process supports all development phases, from the definition of objectives to the management of measurement campaigns. Beyond data collection, we include the analysis of results, verification against design expectations and, where necessary, the updating of the test plan. We provide documentation and reports for homologation, supporting the client throughout the entire process. The integration of simulation and testing creates a continuous improvement loop that leads to more efficient, lighter and more competitive products.

We operate across the entire product development cycle thanks to multidisciplinary expertise covering:

  • FEM structural simulation;
  • CFD fluid dynamics & aerodynamics;
  • Thermal and thermo-structural analyses;
  • Multi-Body Dynamics (MBD);
  • Electromagnetics (EM/EMF);
  • Mechanical, thermal, vibrational and functional testing;
  • Data correlation and digital twin modelling;
  • Design and manufacture of test benches and mechatronic systems.

The integration of simulation and testing allows us to reduce development times and risks, anticipate technical issues and validate robust, high-performing and optimised solutions.

CAE (Computer Aided Engineering)

The CAE area predicts and optimises the behaviour of products and systems through advanced numerical models. Activities cover structural, fluid-dynamic, thermal, dynamic and electromagnetic analyses, with a multi-disciplinary approach to anticipate design criticalities, improve performance and reduce development time and costs.

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Structural FEM
Analysis

  • Linear and non-linear static analyses;
  • Modal, harmonic, transient and shock dynamic analyses;
  • Explicit simulations for impacts and crashes;
  • Verification of welds, bolting and joints;
  • Compliance verifications EN, ASME, FAR, DNV, EASA;
  • Weight/stiffness optimization.
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Thermal &
Thermo-Structural

  • Steady-state and transient thermal analyses;
  • Thermal shock and thermo-mechanical fatigue (LCF/HCF);
  • Thermal design for power electronics;
  • Thermo-mechanical coupling;
  • Conduction, convection, radiation;
  • Critical thermal transient analyses.
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CFD &
Aerodynamics

  • RANS/URANS and LES models;
  • Fluid dynamics of compressors, fans, HVAC;
  • Aerodynamics of drones, UAVs, vehicles;
  • Coupled thermo-fluid dynamics;
  • Modeling of moving domains and rotating interfaces;
  • Integration with wind tunnel and water basin tests.
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Multi-Body
Dynamics (MBD)

  • Kinematic and dynamic modeling of mechanisms;
  • Calculation of inertial, contact and actuation forces;
  • Study of kinematic chains and multi-link systems;
  • Transfer of dynamic loads to FEM models;
  • NVH evaluations and identification of dynamic critical issues.
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Electromagnetics
(EM/EMF)

  • Magnetostatic and magnetodynamic simulations;
  • Calculation of flux density and magnetic forces;
  • Coupled thermo-electromagnetic analyses;
  • Simulations of actuators, solenoids, motors;
  • Study of transient phenomena and variable conditions.
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Multidisciplinary Models
& Digital Twin

  • 1D–3D model coupling for mechatronic systems;
  • Reduced order models (ROM) for fast simulations;
  • Integrated multiphysics simulations;
  • Digital Twin for prediction and diagnostics;
  • Validation through test-simulation correlation.

Testing

The Testing area performs physical verifications, functional tests and environmental tests to validate the actual behaviour of components and systems. Through customised test benches, high-precision measurements and numerical–experimental correlation, we reproduce critical operating conditions, certify product reliability and support the entire qualification and validation path.

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Mechanical, Thermal
and Environmental Testing

  • Tensile, bending, compression and creep tests;
  • LCF/HCF fatigue and accelerated thermal cycles;
  • Random, sinusoidal, shock and PSD vibrations;
  • Climatic tests: temperature, humidity;
  • Salt-spray corrosion tests;
  • Thermal shock with extreme gradients.
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Test Campaign
Design

  • Definition of test requirements and specifications;
  • DVP&R and V&V validation plans;
  • Procedures, criteria and flow charts.
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Data Acquisition &
Data Correlation

  • Thermal, vibrational, electrical and mechanical measurements;
  • Signal processing and advanced filtering;
  • Comparison of real measurements vs FEM/CFD/MBD simulations;
  • Refinement and calibration of numerical models;
  • Detailed technical reporting.
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Advanced Functional
and Dynamic Testing

  • Pressing with vibration and dynamic friction;
  • Wear tests and reconstruction of wear profiles;
  • Tests for turbomachinery and rotordynamics;
  • Electromechanical and electronic functional tests;
  • HALT/HASS stresses;
  • Torsional and rotational vibration tests.
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Test Bench Design
and Construction

  • Concept, specification, mechanical/electronic/software design;
  • R&D, endurance, functional and EOL test benches;
  • Bench validation (FAT) and commissioning;
  • Equipment for complex and high-precision tests.
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Laboratory
Instrumentation

  • Climatic and thermo-hygrometric chambers;
  • Thermal shock;
  • Salt-spray;
  • Shakers and vibration systems;
  • Multi-channel high-frequency DAQ;
  • HPC infrastructure for post-processing.

Our method

The mission of the CAE & Testing Department is to support companies and R&D centres in the development of reliable, high-performing products that comply with regulations, by integrating advanced numerical simulation, physical experimentation and the design of test systems. We work with a multidisciplinary, rigorous approach aimed at reducing design risks.

What sets us apart:

  • Full integration of CAE + Testing + Laboratory.
  • Multidisciplinary approach (structural, fluid dynamics, thermal, EM, dynamic).
  • End-to-end design of test benches and custom equipment.
  • Continuous numerical-experimental correlation.
  • Tailor-made solutions for R&D, qualification and industrialisation.
  • Focus on technical quality, robustness of results and reduced time-to-market.

We apply advanced CAE & Testing methodologies to anticipate critical issues, reduce development costs and prevent errors that, if detected in production or in service, would have far greater technical and economic impacts.” — Eng. Giuseppe Sgrò

Ing. Giuseppe Sgrò
System of Competences - COMPOLAB

A system of competences

An integrated ecosystem. Five technical departments, a shared method and the ability to orchestrate diverse
know-how into coherent solutions. This is the value we provide to our clients.

Departments

Five integrated technical divisions for multidisciplinary solutions.

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Applications

Engineering solutions for aerospace, automotive, energy and other sectors.

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Consulting

Strategic support for the transformation of business processes.

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Your technology partner

Whatever your industrial need,
we are ready to build the solution together.

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