Test how your product performs — before you ever build it.
Rev1 Technologies uses advanced engineering simulation — structural FEA, CFD, thermal, crash, NVH, fatigue, and Moldflow — to predict real-world behavior, cut prototype cycles, and de-risk your design early.
Think of it as a virtual test drive: instead of building expensive physical prototypes, we model different scenarios digitally, find the problems, and engineer the best solution before anything is cut, molded, or machined.
Have a part or design to validate? Let's simulate it.
Send us the geometry, the loads, and the environment — and we'll come back with a simulation plan, scope, and timeline, usually within one business day.
See how it performs in the real world — virtually.
Simulation lets us test a product against real-world physics before it exists. Instead of building prototype after prototype, we model the scenarios that matter, answer the hard questions early, and iterate at the speed of software.
- Reduced physical testing — fewer prototype builds and test rigs.
- Better performance & safety — problems found and fixed before tooling.
- Time & cost savings — shorter development cycles, smarter R&D decisions.
Advanced simulation, across the physics that matter.
Engage us for one analysis or a full multiphysics program — each capability stands on its own and feeds the next.
Computational Fluid Dynamics (CFD)
How air and liquids move around and through your product.
- Aerodynamics & drag
- Cooling & heating flow
- Complex internal/external flow
Structural FEA
Stress, deflection, and strength under real loads.
- Linear & non-linear analysis
- Static & dynamic loading
- Contact & assembly stress
Moldflow Analysis
For plastic parts — manufacturability before the tool is cut.
- Fill, pack & cooling
- Shrinkage & warpage
- Lower part & tooling cost
Crashworthiness & Safety
Impact performance against global safety standards.
- Frontal, side & rear impact
- FMVSS, ECE & IIHS targets
- Airbag & restraint studies
Durability & Fatigue
Predict lifetime under repeated real-world stress.
- Fatigue life prediction
- Weak-point identification
- Design strengthening
Thermal & Cooling
How heat builds, moves, and is managed.
- Thermal management
- Cooling-system optimization
- Thermal-distortion control
Acoustics & NVH
Noise, vibration, and harshness — tuned for comfort.
- Noise reduction
- Vibration & modal studies
- Acoustic tuning
Topology & Optimization
Remove mass while keeping the strength you need.
- Topology optimization
- Free-size / thickness tuning
- Lightweighting
Kinematics & Motion
How moving parts interact across an assembly.
- Mechanism & motion studies
- Interference & clearance
- Multibody dynamics
Not just finding problems — finding the best solution.
Simulation points to where a design is weak, heavy, or over-built — then optimization tells us how to fix it. We tune geometry and material distribution to hit strength, weight, and cost targets at the same time.
- Topology optimization — put material only where the load path needs it.
- Free-size optimization — tune thickness to balance strength and weight.
- Linear & non-linear analysis — understand behavior across the full load range.
A great design has to be manufacturable.
We simulate the process, not just the part — so the design that passes analysis is also the design that can actually be made, repeatably and at cost. That means fewer surprises on the floor and at the tool.
- Metal forming & stamping — formability, springback, and thinning.
- Tube bending & extrusion — process feasibility and defects.
- Casting, forging & injection molding — fill, solidification, and quality.
Comprehensive analysis, one accountable partner.
From fluid dynamics to crash analysis — the full physics spectrum under one team.
Trusted by leaders in aerospace, automotive, medical, defense, and heavy equipment.
Fewer prototypes and faster development cycles — problems caught before tooling.
Optimized for safety, performance, and efficiency, not just passing a single check.
On-site, off-site, or hybrid — the engagement bends to fit your program.
Simulation tied to our in-house design, printing, scanning, and inspection.
From geometry to an answer you can act on.
Define
We agree the question, the loads, boundary conditions, and success criteria, then scope the study.
Model
CAD is cleaned and meshed, materials and contacts applied — a model that reflects reality.
Simulate
We run the FEA / CFD / thermal / crash solve across the scenarios that matter.
Interpret
Results are reviewed by real engineers — what's driving stress, flow, heat, or failure.
Optimize
We recommend and re-run design changes to hit strength, weight, and cost targets.
Report
You get clear results, plots, and engineering recommendations you can act on.
Built to survive the real world — not just the ideal case.
Real products face random vibration, variable loads, and extreme environments. We simulate that variability so your design is robust across the operating envelope and meets its safety standards with margin.
- Random vibration & load — behavior under real duty cycles.
- Extreme-environment robustness — thermal, mechanical, and multiphysics.
- Standards compliance — designs that meet the required safety margins.
Simulation for demanding industries.
Aerospace & defense
Aerodynamic optimization, structural integrity, thermal, and reliability for mission-critical parts.
Automotive & mobility
Crashworthiness, NVH, and durability studies for safer, quieter, longer-lived vehicles.
Medical & dental
Thermal and material analysis, durability testing, and regulatory-compliance support.
Heavy truck & equipment
Fatigue analysis and structural assessment for heavy loads — with cost optimization.
Consumer products
Material optimization and manufacturing-feasibility analysis to speed products to market.
Tooling & automation
Tool and fixture analysis plus automation-system simulation for productivity on the floor.
Simulate the machines that make the parts.
Beyond the product itself, we model tooling, fixtures, and automation — validating motion, clearance, and cycle behavior before hardware is committed, so the cell works on day one.
- Fixture & tool analysis — stiffness, clamping, and load paths.
- Automation-system simulation — motion, reach, and interference.
- Productivity optimization — cycle time and throughput studies.
Design smart from the start.
Catch the problems in software, not in steel — and get to a validated, manufacturable design faster.
A global network behind a local partner.
Our simulation work plugs into Rev1's wider engineering and manufacturing network. We bring suppliers in early, act as the bridge between your team and the people who build the parts, and keep everyone aligned — so analysis turns into a real, manufacturable result.
- Early supplier integration to de-risk the design.
- One accountable partner from analysis to production.
- On-site, off-site, or hybrid collaboration.
Engineering simulation — common questions.
What types of simulation do you run?
Structural FEA, computational fluid dynamics (CFD), thermal and cooling, crashworthiness and safety, NVH and acoustics, durability and fatigue, Moldflow, plus topology optimization and kinematics — single studies or full multiphysics programs.
What do you need from me to start?
CAD geometry (or a part we can 3D-scan), the loads and boundary conditions, the operating environment, and what "good" looks like. If you're not sure, we help define the study on a short call.
Can simulation really replace physical testing?
It dramatically reduces it. We validate designs virtually to cut the number of prototype builds and test rigs, then focus physical testing on confirming the final design rather than exploring every option.
Do you only analyze, or can you fix the design too?
Both. Because we have in-house design and engineering, we don't just report a problem — we recommend and re-run design changes to hit your strength, weight, and cost targets.
How do you protect my IP?
NDAs are standard and confidentiality is the default. Your CAD, data, and results remain your property.
What does a simulation project cost?
It depends on the physics, model complexity, and number of scenarios. Send the geometry and goals and we'll scope a plan with a clear timeline and price, usually within one business day.
For immediate assistance:
(248) 707-2950