ESI’s Virtual Prototyping helps Farasis Energy eliminate physical prototypes

ESI Group, leading innovator in Virtual Prototyping software and services for manufacturing industries, helped Farasis Energy, a Chinese-American battery provider, win in record-breaking time, a call for tenders made by a premium German automotive OEM.

Thanks to ESI's expertise, the reliability of the virtual prototype of the new Farasis battery model was decisive in a “zero real prototype” procedure, stipulating the elimination of any physical prototype.

The move of the automotive industry toward electrification is seemingly unstoppable. Manufacturers are announcing aggressive plans for Electric Vehicle (EV) production. So, it's no wonder that new players are entering the market, breaking the traditional rules of product design - new players like lithium-ion battery maker Farasis Energy.

Looking to collect wins in this fast-growing market, the team at Farasis relied on ESI's expertise to prove to a major German car maker that they were the best supplier - based solely on a virtual prototype. This collaboration around ESI's Virtual Performance Solution (VPS) allowed to virtualise and secure the behaviour of the battery in vibration or vehicle crash situations.

Dr. Matt Klein, Advanced R&D Director at Farasis Energy, emphasised the key role ESI played in this project: “Half-way through the bidding process, the manufacturer actually decided to remove the physical prototype step - they would make their decision based on the virtual prototype. In just 8 months, we went from limited Virtual Prototyping capability to winning those bids. The head of the whole programme conducting the bidding process went out of his way to tell us that the mechanical simulation was an instrumental part in helping us get the design approved. We could not have done that without ESI. Our partnership with ESI is truly strategic in bringing our simulation capabilities to a global leading standard.”

Farasis relied on ESI's proven knowledge of the automotive industry and ability to provide real results, virtually, thanks to virtual prototyping. The capability to build a global model, covering several engineering disciplines, led to a highly efficient workflow and ultimately a cost-effective solution for Farasis.

Since their win, Farasis has opened a new factory on-site in Germany, dedicated to the research & development of their batteries for the German car maker. ESI is now putting in place a platform for Farasis' international team of simulation engineers, one that is fully automated and customised to their way of working.

Thanks to this Platform, the Farasis team will work together - regardless of what continent they are on - with great efficiency and transparency, on common Virtual Prototyping models. And what began as a bi-lateral partnership has quickly evolved into an ecosystem comprised of three major players - Farasis, ESI Group, and the automotive manufacturer - all hungry to tap into the EV market.