In product development, getting design right the first time isn’t just important—it’s essential. As products become more complex and time-to-market expectations shrink, engineering teams are under more pressure than ever to deliver reliable, high-performing designs without the costly delays of physical prototyping. That’s where simulation plays a critical role—and where Creo Simulation stands out. In this post we’ll answer the question “what is Creo Simulation”, what it offers, and what that could mean to your company!

What is Creo Simulation?

Creo Simulation, aka Creo Simulate, is an advanced simulation extension within the Creo CAD platform that empowers engineers to validate designs earlier in the product development cycle. With built-in Finite Element Analysis (FEA) capabilities, users can perform structural, thermal, and vibration analyses directly within the modeling environment. This eliminates the need to export models to a separate tool, reducing time and preserving design intent.

Whether you’re optimizing a bracket for strength, ensuring thermal reliability of electronics, or validating vibration tolerances in assemblies, Creo Simulation enables you to make informed design decisions quickly and accurately.

Why Simulation Matters in Design

Traditionally, simulation was reserved for specialists late in the design process—often after costly prototypes had already been built. This reactive approach risks identifying critical failures too late, leading to expensive rework and delays.

By embedding simulation directly into the CAD workflow, Creo Simulate allows engineers to validate performance as they design. This proactive strategy not only prevents failures but also enables teams to create better, more reliable products faster and at a lower cost.

Core Functionality of Creo Simulate

Creo Simulation supports a variety of simulation types that are essential for real-world product validation. It equips design engineers with powerful analysis tools right inside their CAD environment, making it easier than ever to test and refine concepts without switching software.

Simulation types include:

All of this happens within the familiar Creo interface, allowing users to stay within their modeling environment. Because it operates on native CAD geometry, simulation updates automatically with design changes—keeping analysis accurate and up to date.

Creo Simulate also features automatic mesh generation, intuitive boundary condition definitions, and robust solvers that balance speed with precision. This makes it accessible for design engineers while still powerful enough for in-depth analysis.

Why Creo Simulate Stands Out

Creo Simulate provides the ideal balance of usability and advanced capability. It bridges the gap between CAD and CAE by offering simulation tools directly to the people who are designing the product.

Its tight integration with Creo means no translation errors, no disconnected geometry, and no loss of time. Designers can test multiple iterations on the fly—without leaving the modeling environment.

Add to that the high accuracy of Creo’s solvers and mesh refinement tools, and you get a platform capable of producing production-ready insights, fast.

Extended Capabilities: Simulation Extensions

Creo Simulate is just the beginning. For users with more complex needs, PTC offers simulation extensions that expand the scope of what can be analyzed—enabling broader testing and more sophisticated modeling.

These extensions include:

These extensions allow users to tailor their simulation toolkit to match the complexity of their projects and industry demands.

Use Cases and Real-World Value

Creo Simulation is used across industries to solve critical design challenges. From aerospace components and automotive brackets to consumer electronics and medical devices, simulation is integral to ensuring performance and safety.

Design teams use it to:

By uncovering potential issues early, companies reduce the need for physical testing, accelerate time-to-market, and cut development costs significantly.

How Creo Simulate Fits into Your Workflow

Creo Simulation is engineered for the design phase—not just post-processing validation. It integrates seamlessly with other Creo simulation tools, forming a scalable simulation ecosystem within the CAD environment. It complements tools like:

Together, these tools create a scalable simulation portfolio. Whether you’re just validating a simple part or tackling complex assemblies, you can match the tool to the task—without leaving Creo. Creo Simulate ensures continuity across your workflow. Geometry stays native. Changes update in real time. And collaboration between design and analysis teams becomes seamless.

Creo Simulate vs. Creo Simulation Live

While both Creo Simulation and Creo Simulation Live (CSL) are powerful simulation tools within the Creo ecosystem, they serve different purposes and stages in the design process.

Creo Simulation Live offers real-time, instant feedback directly within the modeling environment as you design—perfect for quick checks and iterative concept development.

Creo Simulate, on the other hand, provides more in-depth, detailed simulations with greater control over setup, analysis types, and result interpretation. It’s ideal for validating final designs with higher accuracy and handling more complex studies such as detailed thermal, modal, and structural simulations. Many teams use both tools together—CSL for quick validation, and Creo Simulate for deeper analysis.

Key Questions Engineering Leaders Ask When Considering Creo Simulate

When product-development teams evaluate simulation tools, they often seek clear answers to: which types of analysis are supported? How is the tool different from general CAD or CAE software? When should simulation be used early in the workflow? Can it handle large assemblies or multi-physics? Below we address these considerations for Creo Simulate.

What is Creo Simulate and what types of analysis can it perform?

Creo Simulate (or Creo Simulation) is PTC’s built-in finite element analysis (FEA) solution embedded within the Creo Parametric environment. It allows engineers to conduct structural, thermal, vibration (modal), and fatigue analyses directly on CAD geometry before prototype manufacture. For design teams needing advanced studies, extensions add nonlinear behavior, mechanism dynamics and multi-physics coupling. In practice, using Creo Simulate means you can export your CAD model for analysis inside the same environment and not rely solely on external CAE tools.

How does Creo Simulate differ from general CAD software or separate CAE tools?

Unlike standard CAD software that focuses primarily on geometry creation and part/assembly modeling, Creo Simulate integrates analysis capabilities directly within the design environment. This means you can apply loads, constraints, and review results without leaving the CAD file. Because it is embedded, the learning curve is lower than standalone CAE tools and you avoid geometry translation or duplication. Compared to dedicated CAE tools, Creo Simulate may have fewer very high-fidelity options, but it excels at design-integrated analysis enabling faster iterations. For many companies, this makes it more practical and efficient for mainstream engineering workflows.

Why should engineers use simulation early in the design process?

Using simulation early (sometimes called “shift-left” analysis) enables engineers to identify performance issues before detailed design or costly prototypes are built. When simulation is delayed to later phases, changes become more expensive and time-consuming. Early simulation helps uncover stress concentrations, thermal hotspots, resonance risks or weak structures when geometry can still change easily. With Creo Simulate tied directly to modeling, teams reduce redesigns, accelerate time-to-market and increase confidence in first-pass success.

Can Creo Simulate handle structural, thermal, and vibration analyses?

Yes. Creo Simulate supports structural (static and dynamic), thermal (steady-state and transient) and vibration/modal analyses as part of its core offering. Engineers can define loads, constraints, material properties and review deformations, stress, temperature distributions or natural frequencies within the same environment. For many standard engineering use-cases this coverage is sufficient, avoiding the need for separate solver environments. This breadth makes Creo Simulate practical for teams designing mechanical systems, housings, and assemblies with combined performance demands.

Does it support large-assembly simulation and multi-physics (e.g., thermal + structural) workflows?

Creo Simulate does support assembly-level simulation, though performance depends on system resources, model simplification, and solver settings. For true multi-physics coupling (such as simultaneous thermal-structural interaction or fluid-structural analysis), an advanced simulation extension or dedicated CAE tool may be required. That said, for many design-centered work-flows, Creo’s capabilities allow simulation of assemblies, vibrating components and thermal loads in the same workflow, which is a major advantage when speed and iteration matter. If your OEM is working with very large assemblies or full vehicle-system simulation, you’ll want to assess whether standard Creo Simulate suffices or requires an upgrade.

What mesh elements and solver options does Creo Simulate offer (e.g., solid, shell, beam elements)?

Creo Simulate supports a variety of element types including solid (tetrahedral/hexahedral), shell and beam elements, allowing modeling of thin-walled components, framework structures or full volumes. The solver options include linear static, modal and thermal analyses in the base package; for more advanced non-linear or transient dynamics, optional extensions may be required. User-defined meshing controls, refined mesh zones and element size settings are included to optimize accuracy vs. runtime. While not every element type of high-end CAE tools may be present, Creo Simulate offers a practical and capable FEA platform for engineering design iteration.

Getting Started with Creo Simulate

Using Creo Simulate is straightforward. It’s designed to be intuitive enough for design engineers and flexible enough for experienced analysts, enabling faster adoption across engineering teams.

Simulation studies live within the CAD model file, so there’s no need to manage multiple versions or external files.

If you’re new to simulation, PTC and partners like EAC offer training, support, and guided implementations to help you get started.

Empowering Engineers to Design with Confidence

Creo Simulate puts powerful, accurate analysis tools directly into the hands of design engineers. By validating products early—within the CAD environment—companies reduce development costs, shorten design cycles, and bring higher-quality products to market.

Whether you’re optimizing structural integrity, managing heat, or minimizing vibration, Creo Simulate helps you make smarter decisions, faster.

Ready to take the guesswork out of design? Explore Creo Simulation or request a demo today!

The majority of businesses aspire to achieve sustainability but often lack clarity on where to begin. Many perceive adopting sustainable practices as a daunting task, believing it necessitates a complete overhaul of their production processes to make a significant impact. However, let me assure you that this is not the case.

So, where should you start your journey towards creating more sustainable product design and manufacturing processes?

To genuinely embrace sustainability, focus on making design decisions at the outset. Designing for repair, reducing material usage, refurbishment, remanufacturing, recovery, reuse, and recycling is crucial. It requires a holistic approach that considers a product’s environmental impact throughout its lifecycle.

Over 80% of a product’s environmental impact stems from design decisions made early on.

Here are three ways design changes can drive sustainability:

Sustainability in Design for Dematerialization

Dematerialization, or material usage reduction, emerges as a crucial strategy for sustainability, aiming to reduce material consumption and weight without sacrificing strength and durability. Leveraging cutting-edge technologies like Generative Design, engineers can optimize designs to use only the necessary amount of material, tailored to specific loads and constraints of each application.

Creo Simulation Live offers a seamless platform for quickly assessing how different materials or reduced material usage affect design performance, enabling adjustments earlier in the design process.

Moreover, with solutions like Creo AMX, designers leverage additive manufacturing capabilities to build structures in the most efficient direction, generating automated supports, and showcasing the potential of lattice structures.

These innovations not only allow for a material reduction but pave the way for lighter, more sustainable products that maintain the required level of performance. As we continue to prioritize dematerialization in manufacturing, we edge closer to a future where sustainability and efficiency are seamlessly integrated into every aspect of product development.

Sustainability in Design for Waste Reduction

Designing for manufacturability and minimizing material waste, such as through minimal stock allowance, ensures efficient use of resources from the outset. By leveraging die casting for near-net shape production throughout the manufacturing process, material waste is significantly reduced to maximize material utilization and minimize scrap generation.

Additionally, utilizing numerically controlled (NC) strategies optimized for fast machining and lower energy consumption, such as high-speed machining (HSM) roughing and finishing, contributes to waste reduction and energy efficiency.

Moreover, designing for ease of service and assembly extends product lifespan and reduces the demand for new products. While some parts of a product may wear faster than others, creating products for easy disassembly eliminates waste because you do not have to throw away the entire product to extend the lifespan.

Accurate documentation of assembly and disassembly instructions empowers users to maintain and repair products, minimizing waste and promoting a more sustainable approach to product lifecycle management.

Sustainability in Design for Energy Efficiency

Engineers globally actively address questions such as, “Can we reduce noise and unneeded energy consumption in design?” and “Can we make our design more thermally efficient?” to pave the way for eco-friendly innovation.

Their goal is to pinpoint areas where energy is wasted, but don’t have the most efficient tools to accomplish that task. Modal analysis and thermal analysis enable more streamlined and environmentally conscious designs. Additionally, tools like Creo Flow Analysis optimizes flow efficiency to ensure that products operate with maximum efficiency, minimizing energy requirements without sacrificing performance.

Furthermore, selecting materials that demand less energy to manufacture and recycle adds another layer of sustainability to the design process and reduces the overall environmental impact from production to end-of-life disposal. Through these proactive measures, energy-efficient product design becomes a tangible pathway towards a more sustainable future.

Sustainable Design Solutions

Our suite of Creo design tools supports sustainable practices:

Designing for sustainability benefits both the environment and businesses. Companies can significantly reduce their environmental footprint by considering dematerialization, disassembly, and behavioral modeling.

By partnering with EAC for solution identification and utilizing PTC’s comprehensive Creo design tools, companies can pave the way for a sustainable future while improving their bottom line. Let’s talk about how EAC can help you identify solutions to help your company embrace sustainable design practices today!

How EZ Tolerance Analysis Makes Your Workflow Less Stressful

Intuitive User Interface

Achieve your goals efficiently with minimal frustration. The EZ Tolerance Analysis extension’s user-friendly UI enables you to maintain a flow and continue work without disruptions as it is integrated into the familiar Creo environment. This mitigates any steep learning curve and helps with productivity to get new users up and running quickly and confidently. If you need help getting set up with the technology, give us a shout. We can help maximize your workforce capabilities and your technology investment.

Complexity Management

The EZ Tolerance Analysis software provides tools and features to manage complex designs efficiently. It offers intuitive interfaces and workflows that simplify processes regarding defining tolerance features. The extension extracts relevant information directly from your CAD models, reducing manual effort and potential errors. Visual dashboards: say goodbye to tedious spreadsheets.

Problem Identification and Resolution

No more flying blind, EZ Tolerance Analysis provides visualizations and statistical outputs that enable engineers to identify potential issues and bottlenecks in the assembly or system. After pinpointing problematic areas, engineers can devise effective solutions – such as adjusting tolerances, redesigning components, or modifying manufacturing processes.

Quick Iterative Design Refinement

Perform your “what-if” scenarios quickly and accurately. Using Sigmetrix technology, get immediate feedback on the effects of tolerance adjustments and trade-off analysis. Engineers can quickly refine and optimize tolerances based on the analysis results, reducing the time required for iterations.

Improved Collaboration

The software facilitates collaboration among multidisciplinary teams involved in the design and manufacturing process. Easily share tolerance analysis data, models, and reports via HTML reports to ensure everyone comprehensively understands design intent and can make informed decisions. Visual and data-backed reports can be shared with the shop floor, suppliers, or other stakeholders, facilitating effective communication and collaboration. Providing clear documentation helps to minimize misunderstandings and costly mistakes, saving time and effort in the design and manufacturing process.

Standards and Specifications Compliance

Ensure compliance with built-in libraries of industry standards and specifications. Engineers can access these libraries to ensure that defined tolerances comply with the relevant standards. Ensure compliance with ASME and ISO standards for your designs and create products that align precisely with customer requirements while operating within acceptable tolerances. This feature helps streamline the process of defining tolerance features by providing pre-defined templates and guidelines that match industry requirements.

Overall, EZ Tolerance Analysis empowers engineers to make data-driven decisions, reduce uncertainty, and enhance the efficiency and quality of the design and manufacturing process. It aids in achieving design objectives, meeting customer requirements, and delivering reliable and cost-effective products.

Back-Up Your cad Designs with Stack-Up Analysis

The technology performs comprehensive tolerance stack-up analysis by applying two methods for increased accuracy and precision- worst-case analysis and statistical analysis.

Worst-Case Analysis: Worst-case analysis, commonly employed for critical components, examines the scenario where each component in the stack-up attains its maximum acceptable measurement.

Statistical Analysis: On the other hand, statistical analysis utilizes statistical distribution models to represent the variation of each component. These distributions are then combined to predict the overall distribution of the assembly measurement.