Advancing Automotive Innovation through Virtual Simulations

Dr. Ivan Erenda, Chief Executive Officer, TPV AUTOMOTIVE

Dr. Ivan Erenda, CEO of TPV Automotive since 2019, brings over 20 years of experience in the automotive industry, specializing in production, supply chain, and business management. He also serves as Chairman of the Management Board of the Slovenian Hydrogen Ecosystem Consortium, promoting sustainable hydrogen solutions. Beyond his industry leadership, he authorizes two books on intuition and decision-making, exploring their role in personal and professional success.

Through this article, Dr.Erenda highlights the transformative role of virtual simulations in automotive development, showcasing their impact on reducing physical prototyping, enhancing material efficiency, streamlining EV component design, and driving innovation in the industry.

The Role of Virtual Simulations in Replacing Physical Testing

Virtual prototyping and simulations are a key part of our development processes at TPV Automotive. They allow us to reduce development time and cost associated with prototype production. We simulate structural integrity, product durability, and crashworthiness through advanced simulations, reducing the need for extensive physical prototypes. Recently, we have also emphasized virtual production process simulation, which allows us to develop the most optimal production process in a virtual environment. The connection between virtual product and process development allows us to see how the production process and vice versa impact the product.

Simulations help us keep the manufacturing of physical prototypes to a minimum, which means great cost reduction. While virtual simulations offer tremendous benefits, there are challenges in simulating factors such as unforeseen mechanical fatigue, local material stresses and specific process-related impacts. Therefore, the products still need to be validated by physical prototype testing. To address these challenges, we adopt a hybrid approach—using virtual simulations for early-stage development and complementing them with targeted and final overall physical testing at our in-house testing facilities to ensure real-world performance and regulatory compliance. We also use experience gained in physical testing to transfer the knowledge back to virtual simulations to ensure progress and improve accuracy with each simulation. With this approach, we support nearly all TRL 1–9 development phases in-house, which gives us a competitive advantage in the market.

“Strive to become a leader in shaping new approaches, technologies, and solutions in your field”

Digital Simulations Driving Material Efficiency in Manufacturing

Virtual simulations have reduced material consumption while maintaining the highest performance standards. A prime example is our development of a lightweight, safety-critical chassis component for BMW vehicles. Using advanced digital simulations, we optimized the design to balance complex geometric, structural, and durability requirements while minimizing material consumption.

This universal solution fits across the entire front wheel drive BMW vehicle platform—from conventional and hybrid drivetrains to fully electric vehicles. From a functional point of view, we managed to reduce the weight of the part by 10% compared to the previous generation and increase its load capacity by 10%. With process simulations, we reduced the process-related scrap by 25%. To put this into perspective, the reduced weight means a 175,000-ton reduction in CO2 emissions over the project lifetime - a quantity that would take 1 million trees 6 years to absorb.

Virtual R&D Tools Streamlining Electric Vehicle Development

Virtual R&D tools have been essential in developing structural elements for electric vehicles. Due to the unique challenges posed by EVs—such as accommodating heavy battery packs while maintaining vehicle safety and reducing weight—advanced simulations allow us to optimize designs more efficiently.

We can simulate and analyze the behavior of structural components under real-world conditions. This enables us to refine designs for crash safety, rigidity and weight reduction without extensive physical testing. For example, in the development of battery trays, virtual simulations help us achieve the balance between strength and weight while ensuring compliance with strict safety regulations.

As a serial supplier of battery trays for EVs, these digital tools allow us to identify and resolve potential manufacturing challenges early in the process, reducing development time and costs. By leveraging virtual R&D, we have successfully shortened design cycles, minimized material usage, and enhanced the structural integrity of EV components we develop and manufacture. With new approaches like welding and manufacturing process simulations, we can keep up with extremely short timelines in the EV industry for prototyping and implementing serial production.

Advice for Aspiring Professionals in Automotive Technology

My key advice for aspiring professionals in the automotive technology space is to build their business strategy around innovation and future-oriented development. Strive to become a leader in shaping new approaches, technologies, and solutions in your field.

Maintaining and continuously developing your core competencies is crucial, regardless of market fluctuations or short-term trends. Staying committed to your expertise and long-term vision will prove far more valuable than frequently shifting your company’s direction in response to temporary industry changes. Consistency in innovation and specialization is the foundation for long-term success in this rapidly evolving sector.