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Advanced Manufacturing

Advanced Manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, etc.

On Time Project Delivery

on time project delivery

With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation

Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

Experienced Engineers

Team of expert engineers with more than 15 years of experience.

FEA and CAE Services

At Zeal 3D, we are at the forefront of innovation, revolutionising the way industries approach engineering challenges through CAE and FEA Analysis for Industrial and Product Design services. Our passion for pushing the boundaries of what is possible drives us to deliver unparalleled solutions that empower businesses to design, optimise, and validate their products with precision and confidence.

Our seasoned project managers bring years of experience, tailoring solutions to meet clients' specific requirements. Leveraging extensive multi-purpose finite element software tools, we conduct detailed product testing, ensuring solutions that meet the highest standards of accuracy.

Our commitment to cost-effectiveness and deep industry knowledge is reflected in our team of highly qualified engineers. Employing the best architectural design and advanced technologies, we provide exceptional drafting services. Our analyses are meticulous, aiding in the reduction of design cycles through optimal design processes and enhanced finite element analysis services.

At Zeal 3D, we bring a holistic approach to CAE and FEA, providing comprehensive solutions that empower businesses to thrive in the dynamic landscape of industrial and product design.

Finite Element Analysis

What is Finite Element Analysis (FEA)?

Finite Element Analysis (FEA) serves as a computational tool extensively employed in the realms of engineering and physics to tackle intricate challenges related to the performance of structures, materials, and systems. This simulation technique dissects intricate physical domains into more manageable components, referred to as finite elements, and subsequently employs mathematical equations for these elements.

This process approximates the overall behaviour of the entire system. Finite Element Analysis, facilitated by FAE Software, finds widespread application in comprehending and predicting the responses of objects and systems under diverse physical circumstances, encompassing mechanical stresses, heat transfer, fluid dynamics, and electromagnetic interactions.

Our FEA Services

Structural Analysis

When it comes to structural analysis, Zeal 3D goes beyond the ordinary. We navigate the intricacies of complex assemblies, ensuring a nuanced understanding of how each component interacts within the larger structure. Our proficiency extends from dissecting single elements to orchestrating analyses for multifaceted systems. Through meticulous FEA, we unravel the mysteries of structural behaviour, providing invaluable insights for engineers and designers.

Thermal Analysis

Thermal analysis is a cornerstone of our FEA capabilities. Delving into the intricate dance of temperature and heat flow, we map out thermal responses with precision. Our thermal analyses extend beyond the superficial, offering a profound understanding of heat dynamics. Whether it's external heat sources or internal heat generation, our FEA studies predict temperature gradients and heat flux. Furthermore, our expertise shines in multi-physics thermo-mechanical simulations, seamlessly integrating thermal and mechanical analyses for a holistic understanding of system behaviour.

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Fatigue and Failure Analysis

Fatigue and failure analysis represent another cornerstone of our FEA services. Constructing high-fidelity FEA models serves as the initial step in anticipating the actual failure of engineering components and structures. Zeal 3D goes beyond model creation, delving into defining failure criteria and comprehending fatigue durability. We possess the capability to predict yielding, time-dependent creep, and overload events in components and structures. Our proficiency extends to the analysis of durability, where we estimate fatigue life in terms of load cycles to crack initiation. Moreover, we predict the subsequent propagation of cracks through parts, offering a holistic view of potential failure scenarios.

Design Optimisation

Design optimisation is a domain where Zeal 3D not only keeps pace with modern engineering but surges ahead. While traditional design methodologies have their merits, our FEA-based design optimisation technology emerges as a more timely and cost-efficient alternative. End-to-end optimisation is our forte, seamlessly integrating FEA insights to refine and enhance designs. The cutting-edge technology of generative design finds a comfortable home in our suite of services, allowing us to not only optimise but also generate finished computer-aided design (CAD) for manufacturing.

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FEA Service
FEA Software

How Does FEA Work?

Finite Element Analysis (FEA) works by dividing a complex system into smaller, simpler elements. Mathematical equations are applied to these elements to approximate the overall behaviour of the system. These steps summarise how FEA works:

  • Discretization: Break down the system's geometry into smaller elements.
  • Equation Formulation: Develop equations describing the behaviour within each element based on physical principles (e.g., equilibrium, conservation laws).
  • Assembly: Combine element equations to create a system of equations representing the entire system.
  • Solution: Numerically solve the system of equations to find unknowns like displacements, stresses, or temperatures.
  • Post-Processing: Analyse and visualise results to understand system behaviour under different conditions.

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By harnessing FEA, Zeal empowers design engineers to:

  • Analyse Product Behaviour: Engineers can gain deep insights into how products respond to real-world conditions, helping them make informed decisions throughout the design process.
  • Predict Failures: FEA can identify potential failure points in a product design, allowing engineers to address these issues before they become critical problems.
  • Optimise Product Design: With FEA, engineers can iteratively refine designs to achieve optimal performance, durability, and safety.

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Benefits of FEA

Finite Element Analysis (FEA) offers numerous benefits across various industries and fields of engineering. Some of the key advantages of using FEA include:

1. Cost Savings: FEA brings the magic of virtual testing and fine-tuning, sidestepping the need for expensive physical prototypes and iterative tests.

2. Design Optimisation: Engineers can fine-tune designs by experimenting with different materials, sizes, and arrangements to attain peak performance and efficiency.

3. Performance Prediction: Finite element method provides insights into how structures and systems will behave under different circumstances. This crystal-clear insight ensures dependability and safety.

4. Risk Reduction: Early warnings are FEA's secret power, unveiling design flaws, weak spots, and potential pitfalls at the outset. This will stave off costly disasters down the road.

5. Time Efficiency: FEA accelerates design timelines, enabling quick exploration of numerous scenarios and making sound decisions in the blink of an eye.

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6. Customization: FEA allows engineers to tailor various designs, adapting to precise requirements and delivering optimal solutions for distinctive applications.

7. Material Savings: FEA helps optimise material usage, thereby reducing waste and overall project costs.

8. Increase in Productivity: FEA contributes to increased productivity by streamlining the design and analysis process. Traditional methods of physical prototyping and testing can be time-consuming and resource-intensive

9. Reduction in Number of Prototypes Required: Traditionally, engineers would create physical prototypes to test and validate their designs. Each iteration of a prototype involves time, cost, and material resources. FEA significantly reduces the need for physical prototypes by allowing engineers to virtually test and analyse various design scenarios.

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CEA Service

What is CAE?

Computer-Aided Engineering (CAE) encompasses the use of computer technology and software tools to assist in the design, analysis, simulation, and optimization of engineering tasks and processes. CAE encompasses a wide range of applications across various engineering disciplines, including mechanical, structural, thermal, fluid dynamics, electrical, and more. Its main goal is to enhance the efficiency, accuracy, and cost-effectiveness of engineering tasks through computational methods.

CAE involves the creation of virtual prototypes and CAE simulations that replicate real-world conditions, enabling engineers to gain insights into the behaviour of their designs without having to build physical prototypes. This helps in identifying potential issues, optimising designs, and making informed decisions early in the design process.

How does computer-aided engineering work?

Modelling: Initially, engineers generate digital portrayals of physical components through 3D modelling software. These virtual models faithfully capture the shape and makeup of the object under design.

Simulation: CAE entails conducting simulations that mirror real-life circumstances and actions. These CAE simulations cover analyses of mechanical stress, fluid dynamics, heat movement, and more. By feeding in various factors and limitations, engineers can observe how the product or system behaves in different situations.

Thorough Analysis: CAE tools meticulously scrutinise the outcomes of simulations, providing valuable insights into facets such as structural robustness, performance, efficiency, and safety. Engineers can spot possible concerns, vulnerabilities, or areas that can be enhanced.

Enhancing Performance: Drawing from the analysis results, engineers can tweak design elements to boost the product's performance and attributes. CAE contributes to refining designs prior to fabricating physical prototypes, leading to savings in time and resources.

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Iteration: Engineers cycle through the steps of modelling, simulating, analysing, and optimising to meticulously fine-tune the design. This iterative loop persists until the intended outcomes are achieved.

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Computer Aided Engineering

Advantages of CAE

Efficiency in Time and Costs: Utilising CAE reduces the necessity for physical prototypes and extensive testing. This leads to quicker cycles of product development and savings in expenses.

Minimization of Risks: Early identification and resolution of potential issues during the design phase help in reducing the chances of failures or flaws emerging later on.

Exploration of Designs: Engineers can swiftly delve into various design options, empowering them to make informed choices about the most suitable design direction.

Complexity Handling: CAE proves especially valuable in managing intricate systems and situations that pose challenges for conventional analysis methods.

Data-Driven Decisions: CAE offers information-rich insights that assist engineers in making knowledgeable decisions about designs and in providing sound justifications for their choices.

Virtual Testing: CAE empowers engineers to put designs through different real-world situations and scenarios that could be tough or unsafe to recreate in actual tests. This covers intense circumstances, like very hot temperatures or strong pressures, assuring that the design can endure a wide array of circumstances.

Industries Relying on FEA and CAE

In various sectors, the use of FEA and CAE simulations is widespread, offering insights into the behaviour of physical systems, products, and processes. Below are some industries where these simulations play a vital role:

Automotive :

FEA and CAE find extensive application in the field of automotive engineering. They help analyse vehicle components, ensuring they are safe, efficient, and perform well. These simulations are crucial for crash tests, vibration studies, and overall structural assessments.


The aerospace industry heavily depends on FEA and CAE to scrutinise aircraft structures, aerodynamics, heat distribution, and fluid dynamics. This ensures the safety and optimal functioning of aeroplanes, spacecraft, and related parts.

Mechanical Engineering:

FEA and CAE are instrumental in mechanical engineering, aiding in the design and evaluation of diverse products like machinery, consumer goods, industrial equipment, and manufacturing processes.

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Civil and Structural Engineering:

Civil engineering benefits from FEA and CAE by analysing the strength, stability, and load-bearing capabilities of structures like buildings, bridges, dams, and other infrastructure projects.

Energy and Power Generation:

The energy sector uses FEA and CAE to understand the mechanical, thermal, and fluid dynamics of power plants, turbines, and heat exchangers, enhancing the efficiency of energy systems.

Electronics and Semiconductor Industry:

FEA and CAE simulations help optimise the performance, thermal control, and reliability of electronic components, circuit boards, and semiconductor devices in the electronics and semiconductor industry.


In the medical device realm, FEA and CAE are used to simulate and evaluate the behaviour of medical devices, implants, and prosthetics, ensuring their effectiveness and safety in healthcare settings.

Oil and Gas:

The oil and gas industry employs FEA and CAE to analyse pipelines, drilling equipment, and offshore structures, enabling the study of components under extreme conditions.

Defence and Military:

FEA and CAE are pivotal in designing and assessing military equipment, vehicles, and structures, ensuring their durability and reliability in challenging operational environments.

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FEA and CAE services
Zeal 3D for FEA and CAE Services

Why Choose Zeal 3D for FEA and CAE Services?

Extensive Experience

With over 10 years of experience in various design and engineering industries, Zeal 3D has gained a wide range of expertise and knowledge. This experience suggests that the company is likely familiar with a wide range of engineering challenges and solutions.

Faster Turnaround

The commitment to delivering projects quickly without compromising quality indicates that Zeal 3D values both efficiency and precision. This can be especially beneficial when you're dealing with time-sensitive projects or tight deadlines.

Comprehensive Solutions

As a leading CAE service provider in Melbourne, Zeal 3D's ability to support the entire product design and manufacturing process, from concept to finalisation, can streamline your project management. This approach can potentially save you time and effort by centralising your design and engineering needs.

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Cutting-Edge Technologies

Incorporating the latest CAD software, advanced 3D scanning, and cutting-edge 3D printing, Zeal 3D excels in providing modern, efficient solutions. This commitment extends to their CAE services in Australia, ensuring top-notch quality and rapid delivery.

Diverse FEA Analysis

Zeal 3D's experience with various types of mechanical and structural engineering analysis problems indicates a broad expertise. This adaptability can be crucial when dealing with complex and varied engineering challenges.

Collaborative Approach

Zeal 3D's commitment to improving design engineers' skills through FEA indicates a willingness to share knowledge and work closely with clients to enhance their understanding of engineering analysis.

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