Three Powerful Methods for Shell Meshing in Ansys: A Comparative Guide 

Introduction

When working with surface body models in Ansys, the method you choose for connecting and meshing components can significantly impact your workflow efficiency and simulation accuracy. Whether you’re analyzing a motorcycle chassis, automotive frame, or any structural assembly, understanding the strengths and limitations of each meshing approach helps you select the right tool for your specific application. 

In this comprehensive guide, we explore three distinct methods for shell modeling and meshing using Ansys Discovery and Mechanical. Using a motorcycle chassis model as the example, each workflow is demonstrated step-by-step, revealing the unique advantages of each approach depending on your geometry, project requirements, and available tools. 

Quick Comparison Table

Feature Shared Topology Connect Mesh Weld Bodies
Automation Level Medium-High Highest High
Geometry Prep Time Low-Medium Low Medium
Handles Overlap Manual workarounds Manual workarounds Automatic
Software Required Discovery Standard Discovery Standard Discovery Premium
Parallel Meshing No Yes Yes
Learning Curve Base bodies only Base bodies only Independent weld materials
Best for Geometric verification Fast workflows Complex assemblies
Video Step-by-Step Tutorial Part 1 Part 2 Part 3

 

Quick Comparison Table

Method 1: Shared Topology Method 2: Connect Mesh Method 3: Weld Bodies
Insert image Insert image Insert image
Overlapping tubes require Pull + Split operations Overlap not recognized contact needed Weld automatically bridges

Method 1: Shared Topology with Surface Extension 

Best for: Users familiar with CAD workflows who want complete geometric control and clean, predictable connections. 

The Workflow 

This geometry-level approach begins in Discovery’s Prepare tab by extracting mid-surfaces from the solid motorcycle chassis model. Using the Mid Surfaces tool with a range selection, the maximum thickness is set larger than the thickest component, and the extend surfaces option is enabled, which automatically extends surfaces to neighboring bodies—eliminating much of the manual work. 

After box-selecting the entire model, Discovery automatically extends most components; after confirming that all bodies are selected, click the green checkmark to create the surfaces. Sometimes, exceptions exist where manual intervention is needed. If there is bad geometry that prevents automatic extension, use the Pull tool to extend edges until they intersect the target body, followed by the Split Body tool to trim excess intersecting surfaces.  

For overlapping components, a specific technique is required: using the Pull tool to extend edges up to surfaces, creating clean connections that will accept shared topology. 

When to Use This Method 

This approach excels when complete control over geometry is needed, and verification of all connections before meshing is desired. It’s particularly valuable for models where geometric relationships must be inspected and validated. However, it requires more hands-on work for complex geometries with problematic intersections, and overlapping bodies need attention. 

Method 2: Connect Mesh Tool 

Best for: Highly automated workflows where geometry preparation time needs to be minimized and parallel processing is beneficial. 

The Workflow 

This mesh-level approach simplifies geometry preparation. Mid-surfaces are still extracted in Discovery, but the extend surfaces option is disabled. Each body is replaced with surfaces in the middle of parent bodies, but critically, nothing extends—the Connect tool handles extension during meshing. 

After updating the geometry in Mechanical, the “Connect” mesh tool can be used by scoping all desired surface bodies and editing values of tolerance and size to produce mesh extensions. 

Method 3: Weld Bodies 

Best for: Models with numerous connections, particularly when different weld types are needed or specific materials must be assigned to connection regions. 

The Workflow 

This approach begins with mid-surface extraction in Discovery (again with extend surfaces disabled), then proceeds to the Assign Weld feature—which requires Discovery Premium. 

Rather than manually selecting each edge in a model with many connections, the distance-based selection filter provides efficiency. The maximum distance is set greater than the largest gap to be connected. After box-selecting the entire model, bodies containing weld elements highlight in orange, while specific edges that will create weld line bodies are highlighted in purple. 

Since the selection filter may capture unwanted edges, the deselection tool removes edges that shouldn’t become welds. Once the selection is finalized and accepted, Discovery creates individual weld bodies highlighted in neon. Each weld exists in the tree as its own body. 

Once you’ve updated your geometry in Mechanical, the Weld mesh tool provides precise control over weld generation. This specialized mesh control gives you flexibility to customize welds according to your simulation requirements. 

The “Modeled As” option lets you choose how welds are represented—select Normal for perpendicular connections, Angled for non-perpendicular joints, or Normal and Angled when your model contains both types. You can assign specific materials to individual welds through the Material detail, ensuring accurate material properties in your simulation. 

For single weld definitions, set Curve Scoping to “Body Selection” and pick the desired weld body from the available list. When you need to create multiple welds sharing identical settings, the worksheet function streamlines the process. Simply change the worksheet detail to “Yes” to open a blank worksheet, then click “Create Controls for All Curve Bodies” to automatically populate it with all available weld bodies. 

After configuring your weld controls and generating the mesh, Mechanical creates each weld with shared nodes at the connection points between bodies, preparing your model for analysis. 

Choosing Your Method 

Based on the demonstrations, here’s when each method excels: 

Use Shared Topology (Method 1) when: 

  • Verification of geometric relationships before meshing is needed 
  • Comfort with CAD workflows and hands-on control is preferred 
  • The model has relatively simple intersections 
  • Geometric accuracy and visual confirmation are critical 

Use Connect Mesh Tool (Method 2) when: 

  • Geometry preparation time needs to be minimized 
  • Large assemblies can benefit from parallel meshing 
  • The model has problematic geometry but limited overlaps 
  • Quick iterations and time efficiency are priorities 

Use Weld Bodies (Method 3) when: 

  • The model has numerous connections to manage 
  • Different weld types are needed (extension, fillet, or both) 
  • Overlapping components are present 
  • Weld properties differ from base material (for structural/fatigue analysis) 
  • The highest level of automation with maximum control is desired 

Key Takeaways 

Throughout these three methods: 

  1. All methods eliminate manual contact definitions—shared nodes handle load transfer automatically 
  1. Prime mesh integration (automatic in 2025 R2, manual selection in 2024 R1+) provides fast, high-quality quadrilateral elements for all approaches 
  1. Geometry complexity matters—Methods 2 and 3 handle problem geometry progressively better than Method 1 
  1. Overlapping components are the differentiator—only Method 3 handles these automatically 
  1. Validation is consistent—”Color by Body Connection” confirms successful shared nodes across all methods 

Conclusion 

These comprehensive demonstrations reveal that modern simulation workflows offer flexibility to match meshing approaches to specific project needs. Whether choosing the geometric control of Shared Topology, the efficient automation of the Connect Mesh Tool, or the sophisticated capabilities of Weld Bodies, each method provides a pathway to accurate, efficient shell modeling in Ansys. 

At DRD Technology, our team helps engineering teams master these workflows through hands-on Ansys training, technical support, and consulting services. Whether new to surface modeling or optimizing established processes, we can guide you toward the most efficient approach for your applications. 

Ready to streamline your meshing workflows? Contact DRD Technology to learn more about Ansys Discovery and Mechanical capabilities or explore our upcoming webinar on advanced meshing techniques. 

Celebrating Kimberly DeLozier: 30 Years at DRD Technology

Introduction

This year marks three decades since Kimberly DeLozier joined DRD Technology. As our Chief Financial Officer, she’s been the architect of the financial infrastructure that has enabled our company’s remarkable transformation from a small regional operation to a multi-state enterprise.

Kimberly came to DRD in 1995 after answering a job ad. The company was in the midst of a significant transition, with around 10-15 employees corporation to an Oklahoma-based business. It was a company finding its footing, and Kimberly would become essential to that journey.

“I like math. I was a STEM girl before it was popular,” Kimberly says about what drew her to finance and accounting. That passion for numbers and systems would prove crucial in the years ahead.

Her first day at DRD presented both a challenge and an opportunity. She arrived to find a desk, a chair, an outdated computer she wasn’t certain could even support an accounting program, and a trial balance. Her mission was clear but daunting: build the accounting department.

Most people would have been intimidated. Kimberly saw it differently. “It was exactly what I was good at and enjoyed the entire process.” She established every system, every process, every control that would eventually support a company many times its original size. That early work became the bedrock of DRD’s financial operations for the next three decades.

 

Stewarding Exponential Growth 

The numbers tell a remarkable story. When Kimberly started, DRD was selling in approximately 5 states. Today the company operates in over 20 states, serving a vastly expanded customer base with a team that has grown proportionally. Through every phase of that expansion, Kimberly has been there, ensuring the financial foundation remained solid even as the company scaled.

“It has been interesting and fun to watch DRD’s growth,” she reflects. The enthusiasm in that statement is notable. After 30 years, she still finds the work engaging, still sees the growth as something worth celebrating.

She never set out to spend three decades at one company, but the decision made sense within the context of her life. Her aunts, uncles, grandparents, and parents all stayed with and retired from the same companies after 20-30 years of service. She grew up watching people build careers through loyalty and commitment.

A Philosophy of Problem-Solving

Kimberly brings a distinctive mindset to her role as CFO. She doesn’t frame situations as challenges to be overcome. Instead, she sees them as issues that require resolution. It’s more than semantics. This perspective strips away the drama and emotion that can cloud judgment during difficult moments.

“I do not look at something as a ‘challenge’ but I look at what is called a challenge as something that needs to be completed or resolved,” she explains. 

That pragmatic, steady approach has been invaluable through market shifts, company growth phases, regulatory changes, and the countless complexities that come with managing finances for an expanding business.

A Commitment to Excellence 

Kimberly’s professional credentials reflect a lifelong commitment to learning and excellence. She was valedictorian of her high school class, an early indicator of the drive that would characterize her career. She earned an associate’s degree in general business from Northeastern Oklahoma A&M College, then continued to Langston University where she completed a Bachelor’s degree in business with an emphasis in accounting.

Two years after joining DRD, she achieved her CPA certification. But she didn’t stop there. While managing her responsibilities as CFO, she pursued and earned a doctorate degree in law from the University of Tulsa and passed the Oklahoma Bar exam. She’s been a practicing attorney for over 20 years, bringing a unique dual expertise to her role.

She maintains active involvement in multiple professional organizations, including the Oklahoma Bar Association, Tulsa County Bar Association, American Inns of Court, Oklahoma Society of CPAs, and the Tulsa Chapter of the Oklahoma Society of CPAs. This continued engagement with the broader professional community keeps her connected to evolving standards and best practices.

Before joining DRD, Kimberly built experience in accounting positions across different industries, including property management and oil and gas. That diverse background gave her the versatility to build systems that could adapt and scale with the company’s needs.

The Foundation of Loyalty 

When asked what has kept her motivated and committed to DRD Technology for 30 years, Kimberly’s answer is refreshingly straightforward: “I enjoy my work and that is all the motivation I have ever needed.”

But there’s another dimension to her loyalty. She speaks with genuine respect about the company’s leadership. “I am privileged to work for three of the most honest, fair, objective, consistent, compassionate men I have ever met,” she says of Andy, Chris, and Dwight. “They are what represents DRD. I respect them.”

That mutual respect between leadership and a key executive creates the kind of culture where people stay, where they invest not just their time but their best thinking. It’s a relationship built over three decades of working together through good times and difficult ones, and it shows in the stability and strength of the organization.

Life in Balance

Outside the office, Kimberly finds her equilibrium on the water, spending time boating and fishing, and in the detailed, meditative work of needlework in its various forms. These pursuits provide a necessary counterbalance to the analytical demands of her professional life.

She’s witnessed significant changes in the finance profession during her career. More women have entered the field, a shift she’s glad to see. Technology has transformed work in fundamental ways. But the core principles that drew her to finance were the logic, the precision, and the satisfaction of building sound systems that remain constant.

The Next Chapter

After 30 years with DRD Technology, Kimberly shows no signs of slowing down. Her view of the company’s future is optimistic and grounded in experience. “I do not think DRD has reached its pinnacle and believe it will continue to grow and only get better.”

This confidence carries weight. It comes from someone who has watched the company grow from 6 employees to its current size, who has built the financial systems from scratch, and who has guided the company through three decades of change. When Kimberly says the best is still ahead, it’s worth listening.

Her story is one of sustained excellence, steady leadership, and the kind of dedication that builds enduring organizations. She found work she loved, leadership she respected, and a company worth growing with. Three decades later, both Kimberly and DRD are stronger for that decision.

The Synopsys-Ansys Merger: Exciting New Opportunities Through Your Trusted Partners 

Introduction

A $35 billion transformation that enhances value for channel partner customers 

After an 18-month regulatory marathon, Synopsys officially completed its massive $35 billion acquisition of Ansys a couple of weeks ago, marking one of the most significant deals in semiconductor design history. The transaction, which closed on July 17, 2025, fundamentally reshapes how AI-powered products will be designed and developed from conception to production. 

The regulatory process forced strategic sacrifices. Synopsys had to divest its prized optical software division, including industry-standard tools like LightTools and RSoft, to Keysight Technologies. Similarly, Ansys was required to sell its PowerArtist power analysis tool. While painful, these concessions cleared the path for a transformative combination. 

Why This Merger Matters: The Silicon-to-Systems Vision 

The union creates something unprecedented in the semiconductor industry: a unified platform spanning chip design through system-level simulation. Here’s why this integration is revolutionary: 

Bridging the Physics-Electronics Gap 

Modern AI systems demand unprecedented integration between electronic design and physical reality. An autonomous vehicle chip, for example, must consider not just computational efficiency, but thermal dissipation, electromagnetic interference, and mechanical stress—all before a single prototype is built. 

Synopsys CEO Sassine Ghazi captured this shift perfectly: “The increasing complexity of developing intelligent systems demands design solutions with a deeper integration of electronics and physics, enhanced by AI.” 

Market Expansion Beyond Semiconductors 

The combined entity now addresses a $31 billion total addressable market, expanding Synopsys’s reach into aerospace, automotive, and industrial sectors where Ansys has deep expertise. This represents a 1.5x expansion of Synopsys’s previous market opportunity. 

AI-Enhanced Design Workflows 

The merger enables AI-driven optimization across the entire product development cycle. Instead of sequential design phases, engineers can now simulate chip behavior within system contexts, dramatically reducing development cycles and improving first-pass design success rates. 

Financial Strength: A Powerful Growth Engine 

The combined entity brings together two financially strong companies with complementary revenue streams and exciting growth potential: 

  • $400 million in projected annual synergies by 2027, driving enhanced profitability 
  • Expected margin expansion of 125 basis points in the first full year post-closing 
  • Ansys contributes an estimated $750+ million to fiscal 2025 revenue 
  • Strong recurring revenue base from both companies’ proven subscription models 
  • Expanded $31 billion total addressable market, growing at approximately 11% annually 

The merger creates a financially robust platform capable of sustained investment in R&D, customer success, and next-generation innovation that will benefit the entire ecosystem. 

Great News for Channel Partner Customers: Enhanced Value and Continuity 

The merger brings exciting new opportunities for customers working with established channel partners, while ensuring the same high-quality support and expertise you’ve come to rely on. 

What Stays the Same: Your Trusted Partnership 

Continuity with Your Current Partner: Your existing relationship with trusted channel partners like DRD Technology remains unchanged and stronger than ever. Elite Channel Partners who have been serving customers for decades continue to provide the same personalized service, expert guidance, and responsive support that has made them industry leaders. 

Proven Support Excellence: Established partners maintain their commitment to customer success with the same dedicated engineering teams, comprehensive training programs, and ultra-responsive support that has earned them recognition as top-rated support providers. Partners like DRD Technology, with over 40 years of Ansys expertise and a 97% year-over-year customer retention rate, continue delivering the exceptional service their customers expect. 

Seamless Transition: Both Synopsys and Ansys have maintained separate support systems during the integration (ACSS for Ansys products, SolvNetPlus for Synopsys products), ensuring zero disruption to your current projects and support needs. 

What Gets Better: Expanded Capabilities and Value 

Access to Integrated Solutions: Your channel partner can now offer you access to a dramatically expanded portfolio that combines the best of both worlds—Synopsys’s industry-leading EDA tools with Ansys’s world-class simulation capabilities. This means more comprehensive solutions for your complex engineering challenges. 

Enhanced Technical Expertise: Elite Channel Partners are expanding their already deep technical knowledge to cover integrated silicon-to-systems workflows. This means even better guidance on optimizing your entire design and simulation process, from chip-level design through system validation. 

Streamlined Procurement: Working with your trusted partner becomes even more valuable as they can now provide access to integrated design workflows without requiring you to manage relationships with multiple software vendors. 

Exciting New Opportunities for Your Business 

Accelerated Innovation: The integrated platform enables faster development cycles by providing a unified design-to-validation pipeline. Your engineering teams can now simulate real-world system behavior directly from the chip design phase, reducing prototyping costs and time-to-market. 

Expanded Application Areas: Channel partners can now support your expansion into new markets and applications with comprehensive tools spanning semiconductors, automotive, aerospace, industrial equipment, and emerging AI-powered products. 

Future-Ready Solutions: The combined platform positions you to take advantage of next-generation AI-enhanced design capabilities as they become available, with your trusted partner guiding you through each evolution. 

What Gets Better: Expanded Capabilities and Value 

Deep Industry Knowledge: Established partners bring decades of experience across multiple physics domains and industries, helping you navigate the expanded capabilities effectively. Their expertise becomes even more valuable as the tool portfolio grows. 

Personalized Training and Support: Elite partners continue providing custom-tailored training programs, application-specific consulting, and the responsive support that ensures your team achieves proficiency quickly with any new capabilities you choose to adopt. 

Long-term Partnership Commitment: The most successful channel partners view software sales as just the beginning of a long-term relationship focused on your success. This customer-first approach becomes even more important as the combined platform evolves. 

How to Choose the Right Optical Tool: Ansys Speos vs. Lumerical vs. Zemax

Introduction

From the smartphone in your pocket to satellites orbiting Earth, optics and photonics are transforming the way we live, communicate, and innovate. As devices become increasingly complex—combining nano- to micro-scale components, selecting the right optical simulation software is critical.

Ansys offers three powerful and complementary tools in its optics portfolio: SPEOS, Lumerical, and Zemax. While they all serve the optical design space, each is built for different levels of simulation, from chip to system to human perception. Understanding their differences will help ensure your team is using the most effective solution for your goals.

Ansys SPEOS: Real-World Light Simulation

Primary Focus: 3D lighting systems, human vision, and environmental interaction.

Best For: Engineers designing lighting systems, sensors, and displays that need to function correctly in real-world conditions.

Why Use It:

  • Simulates how light behaves in real environments.
  • Evaluates visibility, glare, and human eye perception.
  • Ensures compliance with industry regulations (e.g., automotive lighting).
  • Perfect for full 3D scene analysis, including camera and sensor packaging.

Example Use Case: Ensuring a car’s heads-up display (HUD) remains legible in all lighting conditions or verifying that a drone’s sensor accurately interprets glare in outdoor environments. Join our upcoming webinar on Camera Development to explore how SPEOS supports vision analysis in real-world environments.

 

Ansys Lumerical: Photonics at the Nanoscale

Primary Focus: Photonic components, integrated circuits (PICs), and light-matter interaction at the nanoscale.

Best For: Designers of photonic communication systems, metamaterials, or CMOS sensors.

Why Use It:

  • Multiphysics solvers for electromagnetic, thermal, and electronic effects.
  • Models waveguides, gratings, quantum devices, and more.
  • Ideal for datacom, optical interconnects, and pixel-level design.
  • Enables chip-to-system simulations with full interoperability.

Example Use Case: Developing a photonic integrated circuit (PIC) for high-speed optical data transmission in datacenter equipment or optimizing nanostructures on an OLED display. Join our upcoming webinar to learn about chip-level simulation, packaging, and thermal performance.

 

Ansys Zemax: Precision Optical System Design

Primary Focus: Imaging systems, lens design, and optical tolerancing.

Best For: Optical engineers building AR/VR systems, microscopes, telescopes, or consumer electronics lenses.

Why Use It:

  • Combines sequential and non-sequential ray tracing in one UI.
  • Offers comprehensive tolerancing and STOP (Structural, Thermal, Optical Performance) analysis.
  • Integrates optical and mechanical design, reducing cross-team errors.
  • Allows for precise manufacturability assessments from concept to production.

Example Use Case: Designing and optimizing the optical path of a VR headset lens, accounting for structural and thermal effects on image quality. Register for our camera development webinar to see how Zemax enhances lens and optical path design.

 

How They Compare

Feature SPEOS Lumerical Zemax
Primary Simulation Type Light in real-world scenes Electromagnetic fields (wave optics) Imaging and lens systems
Key Focus Illumination, sensors, vision Photonic ICs, nanostructures, optical chips Lens design, tolerancing, STOP analysis
Industry Use Cases Automotive, aerospace, consumer devices Semiconductors, datacom, quantum tech Medical optics, consumer electronics, defense
Integration Capabilities CAD tools (CATIA, SolidWorks) Photonic EDA, circuit tools FEA tools, CAD, mechanical design environments
Simulation Scale Macro/system-level Nano/device-level Meso/system-level (lens to system)

Want to see these tools in action?

Check out our upcoming webinars, including:

  • July 8 at 9AM (CDT) – Camera Development: Leveraging Zemax for lens design, Lumerical for image sensor optimization, and SPEOS for vision analysis.
  • July 15 at 9AM (CDT) – Human Factors in Lighting Design: Discover how lighting perception and key metrics impact usability and safety. 
  • July 22 at 9AM (CDT) – Advancing Metalens Design: See simulation workflows using Lumerical and Zemax for next-gen metalens design. 

How Subtle Nozzle Modifications Make a Big Impact

Introduction

In many automotive and industrial applications, the performance of liquid spray nozzles can significantly affect efficiency, lubrication, combustion, or cooling. Despite their importance, engineers often rely on assumptions or trial-and-error testing, which can lead to sub-optimal results. For applications where liquid behavior is difficult to characterize, having accurate models is essential for making informed design decisions.

Anticipating how spray patterns change with minor geometric modifications can reduce uncertainty in the design process. This brief study demonstrates one approach to using CFD for rapid nozzle prototyping.

To showcase the capabilities of Ansys Fluent in modeling liquid sprays across various applications, a simple case study is presented. Both cases use the Volume of Fluid (VOF) model, as shown in the animation below, with identical solver settings to isolate the effect of nozzle geometry.

Could a small geometric change to the nozzle lead to more optimal spray distribution?

To find out, we used Ansys Fluent’s Volume of Fluid (VOF) model to simulate and compare the spray characteristics of two nozzle designs under identical operating conditions in our recent webinar.

Comparing Two Nozzle Geometries Under Identical Conditions

The two nozzle designs depicted below are used for this evaluation.

Case 1: Straight Nozzle Design

This design features a cylindrical outlet with sharp edges. The geometry allows the fluid to exit the nozzle along a more direct path, resulting in a relatively narrow spray pattern in the simulation.

Case 2: Rounded Nozzle Design

This version includes a smoother, rounded transition from the internal chamber to the nozzle throat. The modified geometry changes the way the fluid exits, producing a noticeably wider and more dispersed spray.

Both cases were simulated using the same transient setup over a 0.25-second interval, with all solver parameters held constant to isolate the influence of geometry alone. Within the simulation domain’s bounding box, normalized mass flux results are displayed at both the midplane and bottom surfaces for comparison, as shown below.

While this comparison focuses on qualitative differences in spray coverage, the same simulation method can be extended to evaluate more complex fluid interactions with CAD geometries. By extracting variables such as heat transfer coefficients, surface wetting behavior, or localized flow rates, this approach supports performance analysis across a wide range of engineering scenarios. When the final nozzle design or arrangement of multiple nozzles is not directly visible (E.g. oil nozzles within an engine or gearbox), simulations can offer critical insights into the impact of design decisions.

Midplane contours of the mass flux for both cases are shown and discussed in the following section.

Observations and Design Implications

  • Straight Outlet (Case 1): Suitable for applications requiring a more focused spray pattern, such as targeted lubrication or fuel delivery.
  • Rounded Outlet (Case 2): Better suited for applications that benefit from broader coverage, such as cooling, surface treatment, or agricultural spraying.
  • Design Insights: Even small geometric changes, such as rounding a sharp edge, can significantly influence spray distribution. CFD modeling offers a practical method for evaluating these effects during early design phases. Asymmetric spray patterns are observed in both cases, which may result from the asymmetric inlet or provide insight into transient start-up behavior in these nozzle designs.

To summarize, these simulations illustrate how subtle geometric changes can be evaluated during early design phases to inform engineering decisions, especially when physical prototyping and testing are time-consuming, impractical, or costly.

See the Simulation in Action

To explore these results in more detail, including how the spray evolves over time and interacts with surrounding geometry, check out the full simulation walkthrough in our recent webinar with Dr. Ted Sperry. He’ll also cover tips for modeling pressure swirl atomizers and other complex spray systems in Ansys Fluent.

Why is Ansys Rocky a Must-Have for Engineers?

Introduction

In the fast-paced world of engineering simulations, Ansys Rocky stands out as a game-changer for particle dynamics. Whether you’re working in mining, pharmaceuticals, agriculture, or any industry that deals with bulk materials, Ansys Rocky provides unmatched accuracy, speed, and scalability in Discrete Element Method (DEM) simulations.

As industries push the boundaries of digital engineering, integrating Ansys Rocky with CFD (Computational Fluid Dynamics), FEA (Finite Element Analysis), and Multiphysics solutions ensures a comprehensive approach to real-world problem-solving. In this blog, we’ll explore how Ansys Rocky is reshaping engineering design and how you can leverage it for optimized results.

What Makes Ansys Rocky Stand Out?

1. Advanced Particle Shapes and Breakage Modeling

Unlike traditional DEM tools that rely on spherical approximations, Ansys Rocky allows for realistic particle shapes, including clusters, fibers, and shells. This results in highly accurate predictions of bulk material behavior, leading to more reliable product designs and operational insights.

2. Seamless Multiphysics Integration

By integrating with Ansys Fluent and Ansys Mechanical, Ansys Rocky enables users to study:

  • Fluid-particle interactions (ideal for industries like pharmaceuticals and food processing)
  • Structural loads due to bulk materials (important in conveyor and mining applications)
  • Thermal effects on particle flow This synergy provides engineers with a holistic understanding of how materials behave under various conditions.

3. GPU Acceleration for Faster Simulations

Time is money, and Ansys Rocky ensures maximum efficiency with its GPU-accelerated solver. Users experience up to 50x faster computation speeds compared to traditional CPU-based solvers, significantly reducing simulation time and enabling rapid design iterations.

4. Realistic Conveyor and Comminution Analysis

For industries dealing with bulk material transport, Ansys Rocky provides detailed conveyor belt wear analysis and crusher/grinder efficiency predictions. These insights help manufacturers optimize equipment lifespan, reduce downtime, and improve overall productivity.

Our exclusive webinar will walk through real-world case studies, demonstrate simulation workflows, and show how Rocky integrates with other Ansys tools effectively. 

Industry Applications

1. Mining and Material Handling

  • Predict and mitigate conveyor belt wear and tear
  • Optimize grinding and crushing efficiency
  • Reduce maintenance costs and improve operational reliability

2. Pharmaceuticals and Food Processing

  • Model tablet coating and powder mixing
  • Improve granulation and capsule filling processes
  • Enhance product uniformity and reduce waste

3. Agriculture and Fertilizer Production

  • Simulate grain flow and storage behavior
  • Optimize fertilizer blending and application processes
  • Reduce handling losses and ensure product consistence

How to Get Started with Ansys Rocky

Step 1: Define Your Simulation Objectives

Identify what you want to achieve—whether it’s reducing equipment wear, optimizing material flow, or improving product consistency.

Step 2: Import and Set Up Geometry

Ansys Rocky allows direct CAD imports, making it easy to create accurate simulations with real-world geometries.

Step 3: Select the Right Particle Model

Choose from a variety of particle shapes and material properties to best represent your system.

Step 4: Run GPU-Accelerated Simulations

Leverage parallel processing for faster and more detailed results.

Step 5: Analyze and Optimize

Use Ansys Rocky’s visualization tools to interpret results and refine designs for maximum efficiency.

Conclusion: Why Ansys Rocky is a Must-Have for Engineers

Ansys Rocky is more than just a DEM tool—it’s a simulation powerhouse that bridges the gap between physics-based modeling and real-world applications. With advanced particle modeling, seamless multiphysics integration, and high-speed processing, it is a must-have solution for industries looking to innovate and optimize their bulk material handling processes.

If you’re ready to take your simulations to the next level, contact us today for a demo or trial of Ansys Rocky and see how it can transform your engineering workflow! Our upcoming webinar showcases the advanced simulation tool designed for modeling granular and discontinuous materials across industries like pharmaceuticals, mining, food processing, and manufacturing.