How Vibration and Shock Simulation Reduces Iterations in Hardware Design

Why Simulating Mechanical Stress Saves Time and Money

In the development of industrial, automotive, and aerospace electronics, mechanical durability is not optional. Devices are exposed to drops, vibrations, impacts, and harsh motion — and failing a qualification test late in development often means costly redesigns and missed launch dates.

That's where vibration and shock simulations come in. These virtual tests replicate real-world mechanical stress, helping teams identify design weaknesses before they commit to physical prototypes. In this article, we’ll explain how they work, where they fit in the development cycle, and how they reduce the number of iterations required to reach a robust design.

What Are Vibration and Shock Simulations?

These simulations are part of finite element analysis (FEA) techniques that use CAD models to predict how an enclosure, PCB, or mechanical assembly will behave under mechanical stress.

Types of Simulations:

• Random Vibration – simulates road, flight, or machinery-induced motion
• Sine Sweep – for resonance detection and modal analysis
• Mechanical Shock – replicates drop tests or collision forces
• Combined Environmental Loads – vibration + thermal + pressure

They can be applied to:

• Enclosures and mounts
• PCB assemblies (rigid/flexible)
• Sockets, fasteners, and connectors
• Battery packs and internal brackets

Benefits of Simulation-Led Design

Typical Simulation Workflow at Promwad

• Modeling and Material Definition: Import STEP/IGES files from CAD tools (SolidWorks, Fusion 360, Altium CoDesigner); define plastic, metal, rubber, and PCB stack-up properties
• Boundary Conditions and Constraints: Mounting points, clamp zones, screw torque, damping layers
• Load Profile Selection: Realistic profiles based on product usage (e.g., ISO 16750-3, MIL-STD-810G)
• Simulation Runs: Modal analysis, stress/strain contours, frequency sweeps, displacement graphs
• Interpretation and Redesign: Reinforce ribs, relocate mounting holes, add damping

Iterate before cutting prototypes

Simulation vs Physical Testing

Real-World Use Cases

• Automotive Gateway
  Problem: PCB cracked near mounting hole after vibration testing
  Solution: FEA showed stress concentration → added fillet + isolation grommet
  Result: Passed ISO 16750-3 on next test round
• Ruggedized Sensor Node
  Enclosure resonance near 250 Hz
  Design modified to shift resonance above operational range
  Avoided use of heavier materials

Common Standards Covered by Simulation

Simulations align with these standards to reduce surprises during lab testing.

Design Tips for Better Vibration Tolerance

• Avoid mounting heavy components near unsupported PCB edges
• Use multiple mounting points to distribute load
• Isolate sensitive modules with rubber grommets or foam
• Simulate screw pull-out and torque-induced deformation
• Ensure cables and connectors don’t transmit vibration

Good mechanical design starts with an understanding of the environments the device will face.

Final Thoughts

You don’t need to wait for your product to fail in the lab (or in the field) to fix mechanical weaknesses. With simulation-driven hardware development, you can validate assumptions early, reduce physical prototyping costs, and pass certifications faster.

Promwad helps companies integrate FEA-based mechanical simulation into their electronics development workflows — so they build stronger, smarter, and safer products.

Let’s simulate your way to first-time-right hardware.