Robotics Simulation

What We Do

Core Simulation Services

From concept validation to full virtual commissioning — we reduce risk, compress timelines, and maximise ROI before you commit to hardware.

Offline Robot Programming

Generate, test, and optimise robot programs entirely in a virtual environment — zero production downtime during development.

3D CAD-to-path program generation
Reach & collision-free path verification
Multi-robot, multi-axis coordinated motion
KUKA.Sim, RobotStudio & Roboguide support

Virtual Commissioning

Validate PLC logic, robot programs, and HMI interactions against a full virtual twin before factory acceptance testing.

Full cell emulation (robots, conveyors, PLCs)
PLC signal simulation & interlocking tests
Safety function verification (speed & zone)
FAT/SAT risk reduction by up to 60%

Digital Twin Development

Build live-linked virtual replicas of your robot cells that mirror real-world behaviour for ongoing monitoring, optimisation, and training.

Real-time OPC-UA data synchronisation
Predictive maintenance insights
Continuous cycle time optimisation
Operator training without machine risk

Cycle Time Optimisation

Simulate and fine-tune robot motion profiles, task sequencing, and cell layouts to squeeze maximum throughput.

Motion-profile speed & acceleration tuning
Deadtime & wait-state elimination
Conveyor-tracking and multi-robot balancing
Throughput KPI reporting before go-live

Feasibility & Reach Studies

Prove automation is viable before capital investment — robot selection, mounting positions, and reachability all validated virtually.

Robot model & payload selection analysis
Workspace envelope & singularity checks
Fixture, tooling & cell layout comparisons
ROI and payback period estimation

Simulation-Based Training

Train operators and programmers on exact virtual replicas of your installed robot cells — safe, repeatable, and always available.

Pendant & HMI operator training modules
Emergency stop & fault recovery scenarios
New-hire induction without halting production
Remote training via cloud simulation access

Offline Programming

Program Robots Without Stopping Production

Offline programming (OLP) is the cornerstone of efficient robotic cell deployment. Instead of tying up production robots for hours of teach-pendant programming, our engineers create, validate, and optimise every robot path in a high-fidelity virtual environment.

We work with Process Simulate (Tecnomatix), RoboDK, RobotStudio, KUKA.Sim, and FANUC ROBOGUIDE to generate collision-free programs for welding, handling, painting, dispensing, and assembly applications. Multi-robot coordination, external axis integration, and conveyor tracking are all within scope.

Once validated, programs are exported directly to the robot controller — dramatically reducing on-site commissioning time and eliminating costly production interruptions.

CAD-driven path generation from 3D part models
Reachability analysis and singularity avoidance
Multi-robot workcell coordination and synchronisation
Post-processing for ABB, KUKA, FANUC, Yaskawa, and more
RoboDK multi-brand offline programming capabilities
Process Simulate cycle time analysis and validation

Discuss Your OLP Project

Virtual Commissioning

Validate Everything Before Hardware Arrives

Virtual commissioning is the most effective way to de-risk automation projects. By connecting your actual PLC code to a physics-based simulation of the entire robot cell — including robots, conveyors, sensors, and safety systems — you can detect and fix integration issues weeks before the physical cell is built.

Our virtual commissioning service covers full signal exchange simulation (PROFINET, EtherNet/IP, OPC-UA), safety zone verification, interlock logic testing, and HMI validation. Clients typically see a 40-60% reduction in on-site commissioning time and a dramatic decrease in late-stage design changes.

We use Siemens Process Simulate, Visual Components, and Emulate3D to create high-fidelity emulations that behave like the real system — giving your engineering team confidence before the first physical cable is connected.

Full cell emulation with PLC-in-the-loop testing
Safety zone and speed monitoring validation
Interlock logic and sequence verification
HMI/SCADA integration testing
FAT/SAT preparation with documented test protocols
Reduced on-site commissioning by up to 60%

Plan Your Virtual Commission

Digital Twin

Live-Connected Digital Twin Solutions

A digital twin isn't just a 3D model — it's a live, data-connected replica of your production cell. Our digital twin implementations synchronise in real time via OPC-UA, feeding production KPIs, predictive alerts, and optimisation opportunities directly to your operations team.

We build digital twins that serve multiple purposes: real-time monitoring dashboards, predictive maintenance analytics, continuous cycle time optimisation, and safe operator training environments. The twin stays current as your cell evolves — making it a living asset that grows in value over time.

Integration with your MES and ERP systems means simulation outputs and OEE data flow directly into your manufacturing execution and enterprise planning tools — closing the loop between virtual design and real-world performance.

Real-time OPC-UA, MQTT & REST API connections
Predictive maintenance via servo load and temperature analysis
What-if scenario testing without touching the live cell
MES/ERP integration for OEE data flow
Continuous cycle time and throughput optimisation
Operator training on exact virtual replicas

Explore Digital Twin Options

Our Approach

Simulation Workflow

A proven five-stage process from CAD import to live deployment — delivering confidence at every step.

01

CAD Import & Cell Setup

Import your cell geometry, robot models, fixtures, and tooling into the simulation environment with accurate kinematics and physics.

3D CAD model import and cleanup
Robot library selection and kinematic setup
Fixture, tooling, and peripheral modelling

02

Path Planning & Reach Analysis

Generate collision-free robot paths, verify reach envelopes, and define optimised motion sequences for every operation.

Collision-free path generation
Workspace envelope and singularity checks
Robot mounting position optimisation

03

Simulate & Validate

Run full-speed simulations including PLC logic, safety zones, and multi-robot coordination to validate the entire cell behaviour.

Full cell cycle simulation
PLC-in-the-loop signal validation
Safety zone and speed monitoring tests

04

Optimise & Fine-Tune

Refine cycle times, eliminate dead-time, balance workloads across robots, and confirm throughput targets are met.

Cycle time analysis and bottleneck identification
Motion profile speed and acceleration tuning
Multi-robot workload balancing

05

Deploy & Commission

Export validated programs directly to robot controllers — commission faster with fewer surprises and documented test results.

Controller-ready program export
On-site commissioning support
Validation report and sign-off documentation

Tools & Platforms

Simulation Software Expertise

We work across all major OEM simulation platforms and third-party tools — your brand, your software, our expertise.

KUKA.Sim Pro

ABB RobotStudio

FANUC ROBOGUIDE

Yaskawa MotoSim

Process Simulate

RoboDK

DELMIA

Visual Components

Plant Simulation

Emulate3D

Gazebo

ROS/MoveIt

Why Simulate First

Proven Benefits

Up to 40% FasterCommissioning time reduction

Early Bug DetectionFix errors at software cost

Lower CAPEX RiskValidate before hardware spend

Safer DeploymentsSafety zones pre-validated

Optimised ThroughputCycle time before go-live

Operator TrainingZero downtime training

Collision DetectionInterference-free paths

PLC IntegrationVirtual commissioning ready

Proven Results

Case Studies

Real challenges. Real simulations. Real results.

Robotic Welding Cell Virtual Commissioning

Automotive BIW Manufacturer

Challenge: 12-robot welding cell with complex multi-axis coordination. Solution: Full virtual commissioning using Process Simulate with PLC-in-the-loop validation before hardware arrival.

Result: 55% reduction in on-site commissioning time. Zero collision incidents at startup.

Cycle Time Optimisation for Palletising Line

FMCG Distribution Centre

Challenge: Palletising cell running 15% below target throughput. Solution: RoboDK simulation identified motion inefficiencies and rebalanced multi-robot workload.

Result: 22% throughput increase without hardware changes — ROI achieved in 3 weeks.

Digital Twin for Predictive Maintenance

Pharmaceutical Packaging Line

Challenge: Unplanned robot downtime causing batch delays. Solution: OPC-UA connected digital twin with servo load analytics and predictive alerting.

Result: 70% reduction in unplanned downtime within first quarter of operation.

Client Feedback

What Our Clients Say

"The virtual commissioning service saved us months of on-site debugging. Our 8-robot assembly cell was running at full speed within days of power-on — something that previously took weeks. The digital twin they built continues to be invaluable for training and optimisation."

— Engineering Director, Automotive Manufacturing Group

Industries

Who We Simulate For

Automotive & BIW

Pharmaceutical

Food & Beverage

Electronics & Semiconductors

Aerospace

Heavy Manufacturing

Logistics & Warehousing

Mining & Resources

Common Questions

Frequently Asked Questions

Which robot brands do you support for simulation?

We support all major industrial robot brands including ABB, KUKA, FANUC, Yaskawa/Motoman, Universal Robots, Nachi, Kawasaki, and Staubli. Our engineers are certified in Process Simulate, RoboDK, RobotStudio, KUKA.Sim, FANUC ROBOGUIDE, and Visual Components.

How accurate are simulation results compared to the real cell?

With proper kinematic models, accurate CAD geometry, and validated motion profiles, our simulations achieve cycle time accuracy within 2-5% of actual performance. Virtual commissioning with PLC-in-the-loop testing catches the vast majority of integration issues before hardware deployment.

What deliverables do we receive after a simulation project?

Every project includes validated robot programs ready for controller export, a comprehensive simulation report with cycle time analysis, collision detection results, reachability studies, and recommendations for cell optimisation. Virtual commissioning projects also include PLC test protocols and sign-off documentation.

Can you work with our existing CAD models and cell designs?

Absolutely. We work with all major CAD formats including STEP, IGES, JT, CATIA, SolidWorks, and Inventor. We can import your existing cell layouts, robot models, fixtures, and tooling directly into the simulation environment — or help you create them if needed.

How long does a typical simulation project take?

Timelines vary by complexity. A feasibility study or reach analysis typically takes 1-2 weeks. Offline programming for a single robot cell takes 2-4 weeks. Full virtual commissioning with PLC-in-the-loop testing ranges from 4-8 weeks. Digital twin implementations are typically 6-12 weeks depending on integration scope.

Do you provide ongoing support after the simulation is complete?

Yes. We offer post-deployment support packages that include simulation model updates as your cell evolves, ongoing cycle time optimisation, digital twin maintenance, and operator training refresh courses. Many clients retain us as their long-term simulation partner for all new automation projects.