GM To Expand Virtual Vehicle Design, Development And Validation

GM is looking to expand its vehicle design, development, and testing using virtual processes. The shift is expected to reduce development time and costs through the elimination of a significant portion of the traditional hardware testing.

In traditional testing and development processes, identifying potential issues could involve significant investments of both time and money. Physical prototypes require adjustments and re-tests, driving up costs. By contrast, the automaker’s new virtual-first approach will allow for immediate fixes during the design phase. This is particularly important for GM’s competitiveness as the rest of the automotive industry speeds up development processes.

Per a report from Rubber News, GM engineering group manager Matthew Wieczorek spoke on the issue during a recent conference. Wieczorek’s comments touched on collaboration efforts with suppliers, a critical component in achieving the proposed virtual transition. Broadly speaking, suppliers must provide accurate component data to ensure seamless integration into GM’s virtual testing models. By closing the gaps between GM’s systems and supplier data, the company will be better positioned to increase virtual vehicle development.

While Wieczorek’s presentation clearly indicated that “GM will move to 100 percent virtual design, development and validation by 2025,” the automaker reached out to Rubber News following the publication of the story that GM doesn’t have plans to shift the whole process to virtual at this point. Rather, it’s looking “at a range of tools and innovations to further enhance our development capabilities, and that helps make our teams even more productive throughout the process,” said a GM spokesperson.

The flexibility of virtual simulations also allows for a broader range of vehicle and component variations. This not only enhances vehicle performance, but also significantly improves durability predictions. Wieczorek highlighted the value of this system, noting that the cost of making adjustments in a virtual model is far less than altering physical components during manufacturing.

Durability is another key focus in this virtual shift. Inaccurate predictions can lead to components that wear out faster than expected, hurting both GM’s reputation and customer satisfaction. To address this, GM is working with partners like Endurica and Tenneco, companies specializing in durability software. In one study, GM tested bushings using two different software systems. The faster system, developed by Endurica, reduced the testing time from 60 days to just 17 hours, allowing GM to simulate more variations and deliver better performance predictions.

This new virtual development approach should dovetail nicely with the automaker’s latest Winning with Simplicity strategy, which is expected to save $200 million in 2024 alone thanks to reduced design and engineering expenses, reduced supplier costs, and streamlined order complexity.