We are witnessing a radical transformation in the manufacturing of metal components for the automotive industry—an evolution in both technology and processes that affects design and production alike. At the heart of this revolution is digital simulation: a set of innovations that allows manufacturers to anticipate material behavior, predict deformation developments, and optimize die design. This makes it possible to prevent errors before physical production even begins, overcoming the traditional trial-and-error method.
In cold forming—a plastic deformation process—extreme precision is required: not only must dimensional tolerances specified by automakers be met, but the durability and long-term performance of the component must also be guaranteed. For this reason, virtual prototyping and simulation software are fundamental to the daily operations at Prodotti EBI. These tools have helped transform our process, enabling us to reduce trial-and-error cycles, contain costs, improve overall component quality, and accelerate the so-called “time-to-market.”
Today, before the physical die is created, we can digitally reproduce the entire forming process, analyzing material flow, stress concentration zones, and potential structural weaknesses in the die with great accuracy. Specialized software tools—such as AutoForm, Simufact Forming, and Deform—allow us to simulate every stage of the process: from the initial die to the finished part, including intermediate operations like blanking, deep drawing, and bending.
This phase, known as “numerical modeling,” enables our engineers to test various design solutions based on specific customer needs, modify the geometric parameters of the dies, assess the actual resistance of the chosen material, and prevent issues like surface roughness or unwanted springback. This makes the entire production flow highly predictive, based on objective and replicable data—going far beyond empirical experience alone.
Predictive design is just one of the many advantages of digital simulation. The adoption of virtual prototyping software also leads to a significant reduction in waste—a key factor for more sustainable industrial processes.
In the automotive sector, in particular, it is essential that metal components meet increasingly stringent sustainability requirements. Digital simulation helps ensure accountability, compliance, and quality control in every single formed and produced component, minimizing the risk of defects that could compromise the vehicle’s value and the brand’s reputation.
Once the cold forming process is digitally validated, the actual die can be manufactured—but virtual prototyping continues to play a key role.
Even at this stage, simulation allows us to anticipate press behavior, calculate the required clamping forces, determine optimal working speeds, and establish the number of forming steps needed to produce the finished part.
Moreover, the integration between digital simulation and CNC control allows for a “full digital” approach: a complete integration between human expertise and machine operation that minimizes the margin of error. The data collected during simulation can be used to precisely set up the machines, ensuring maximum consistency between the virtual design and the final product.
Thanks to simulation software, we can now envision the future of industry: the predictive factory. A production environment where data collection and processing, combined with artificial intelligence, enable real-time simulation of the entire life cycle of a metal component—from design to final production.
Predictive manufacturing will not only drastically reduce development times, but also ensure increasingly tailored responses to the needs of automotive manufacturers. Digital simulation will no longer be just a design or forecasting tool—it will become a true strategic asset. And at Prodotti EBI, we are ready to embrace it fully and position ourselves as a go-to partner.
At Prodotti EBI, digital simulation is a core part of our design methodology. Thanks to a specialized technical department and the use of next-generation software, every metal component is studied in detail from the earliest design stages, reducing the risk of errors and enhancing the final product’s quality.
Simulation, metallurgical expertise, and advanced cold forming technologies are what enable us to offer our customers high-performance solutions—even for the most critical automotive applications. We are convinced that the future of manufacturing lies in the virtualization of production processes.
Let’s step into the future together!