Finite Element Analysis Services

Computer Aided Engineering
20+Years Experience
500+Projects Delivered
  • AI-augmented engineering workflows
  • 24/7 onshore-offshore delivery
  • Quality-first methodology

Service Overview

Finite Element Analysis Services

AES provides expert finite element analysis services that reduce design risk and accelerate product validation. Our team brings 20+ years of experience across 500+ completed projects worldwide. From structural FEA services for linear validation to nonlinear crash simulation and fatigue life prediction, our FEA consulting team is available 24/7 to support your project deadlines.

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Solver Toolkit
ANSYS Mechanical Abaqus NASTRAN HyperMesh LS-DYNA

What We Offer

Solutions We Provide

Targeted engineering solutions built around your industry challenges and delivery timelines.

Battery Pack Structural Analysis and Durability

Linear and nonlinear FEA for battery pack enclosures, module holders, and structural components under mechanical and thermal loads.

Crash Test Simulation

Explicit dynamics crash simulation using LS-DYNA for battery pack protection, occupant safety, and structural integrity under impact events.

Battery Pack Fatigue and Durability Testing

Fatigue life prediction and durability analysis for battery pack components subjected to road load, vibration, and thermal cycling.

EV Powertrain Structural Validation

FEA-based structural and thermo-structural validation of EV powertrain components including motor housings, inverters, and mounting brackets.

NVH Analysis for EV Platforms

Modal and harmonic response analysis to characterize vibration behavior and reduce noise in electric vehicle platforms.

Sector Expertise

Industries We Are Experts In

Automotive and Electric Vehicles (EV)

Battery and Energy Storage

Aerospace and Defense

Electronics and Semiconductor

Data Centers

Industrial and Heavy Engineering

Consumer Electronics

Renewable Energy

What We Deliver

Specialized Capabilities in Finite Element Analysis Services

Section 01

Structural FEA

Linear and nonlinear simulation

Our structural FEA services cover the full range of linear and nonlinear structural responses. We model simple load-bearing components as well as complex assemblies under combined mechanical, thermal, and pressure loads. Every finite element analysis includes mesh convergence studies, validated boundary conditions, and fully post-processed simulation reports.

  • Linear static stress and deformation analysis
  • Geometric and material nonlinear FEA
  • Contact and large deformation simulations
  • Buckling and structural stability analysis
  • Pressure vessel and piping FEA (ASME, EN13445)
  • Mesh convergence and sensitivity studies
Structural FEA
Section 02

Thermo-Structural FEA

Sequential and fully coupled

Our thermo-structural FEA simulation services couple heat transfer and structural mechanics in a single analysis. This gives engineering teams a clear picture of thermal hotspots, thermally induced stress, and expansion mismatches before any prototype is built. Widely used for electronics enclosures, engine components, and pressure vessels across aerospace, automotive, and energy sectors.

  • Steady-state and transient thermal FEA
  • Thermal-structural coupling (sequential and fully coupled)
  • Thermoelastic stress and thermal fatigue analysis
  • Electronics and PCB thermal-structural validation
  • Thermal expansion and joint mismatch analysis
  • Refractory and high-temperature component simulation
Thermo-Structural FEA
Section 03

Explicit Dynamics — Crash and Durability

LS-DYNA and ANSYS Explicit

Many engineering teams choose to outsource finite element analysis for crash and impact work to AES because of our hands-on experience with LS-DYNA and ANSYS Explicit. We simulate wave propagation, material failure, and large plastic deformation for crash, drop test, and blast scenarios across automotive, defense, and packaging applications.

  • Automotive crash and occupant safety analysis
  • Drop test and impact simulation
  • Blast and shock wave propagation
  • Bird strike and foreign object damage (FOD)
  • Metal forming and stamping process simulation
  • Penetration and ballistic resistance analysis
Explicit Dynamics — Crash and Durability
Section 04

Noise, Vibration and Harshness (NVH)

Modal, harmonic and random

Our FEA consulting services for NVH analysis cover modal, harmonic response, random vibration, and acoustic-structural coupling. We identify resonance risks and dynamic failure modes early in the design cycle, helping automotive, industrial, and aerospace clients reduce noise and improve structural durability.

  • Free and constrained modal analysis (frequencies and mode shapes)
  • Harmonic response and frequency sweep analysis
  • Random vibration analysis (PSD loading)
  • Response spectrum analysis (seismic and shock)
  • Acoustic-structural coupling for radiated noise prediction
  • Rotating machinery critical speed and whirl analysis
Noise, Vibration and Harshness (NVH)
Section 05

Fatigue, Creep and Fracture Analysis

S-N, E-N and Paris law

Our FEA simulation services for fatigue and fracture use stress-life (S-N), strain-life (E-N), and fracture mechanics methods to predict component life under cyclic and sustained loading. We pinpoint critical failure zones and recommend targeted design changes before components reach the field, across oil and gas, power generation, and automotive industries.

  • Stress-life (S-N) and strain-life (E-N) fatigue analysis
  • High-cycle and low-cycle fatigue life prediction
  • Creep and viscoplastic analysis for high-temperature components
  • Fracture mechanics: stress intensity factor (SIF) and CTOD
  • Fatigue crack growth simulation (Paris law)
  • Weld fatigue assessment (IIW, BS7608 standards)
Fatigue, Creep and Fracture Analysis
Section 06

Sub-Modeling and Topology Optimization

Lightweighting and design refinement

This is the most advanced layer of our finite element analysis services. Sub-modeling gives high-resolution stress results on critical regions without the cost of refining a full model. Topology optimization then removes non-load-bearing material systematically, producing lighter and stiffer designs ready for additive manufacturing and casting workflows.

  • Global-to-local sub-modeling for critical stress regions
  • Topology optimization for lightweighting (AM and casting)
  • Shape and size parametric optimization
  • Design of Experiments (DOE) and surrogate model FEA
  • Sensitivity analysis and design variable ranking
  • Adjoint-based structural shape optimization
Sub-Modeling and Topology Optimization

Get Started

Need a trusted Finite Element Analysis Services partner for your next engineering project?

Talk to our senior engineering team about your project scope, timelines, and technical requirements. We respond shortly.

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500+ Projects
100+ Engineers
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Sarnath R

Sarnath R

Director of NPI & CAE

Sarnath is a NPI and CAE professional with 25+ years of experience in providing wide range of solutions to sectors like Automotive, Semiconductor, product development, Fenestration and Heavy engineering. A multifaceted personality who steers operations including Admin, HR, Proposal Engineering, Project management for AES India and USA. He is responsible for delivering projects in Product development and CAE and validating the same. Handled team sizes of 20 members constituting a combination of Design, FEA, CFD and product Engineers/managers. Manages Proposal engineering and overall operations. Coordinates seamlessly with the Client, Team, Vendors and Management to provide quick, organized and quality solutions. Innovative thinker who provides solutions at very critical phases of design to minimize losses that occur after realization of product.

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