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How Virtual Design Can Change the Future of R&D

Written by Randy Rozema - Director Acoustics & Vibration | Aug 8, 2025, 4:00:00 AM

Integrating Virtual Design and Physical Testing for Greater Efficiency

In today’s competitive landscape, the world of Research and Development (R&D) is undergoing a significant transformation, moving away from traditional methods and embracing the seamless integration of virtual and physical testing. This shift, which is rapidly evolving from a niche concept into a standard practice across many industries, is primarily fueled by advancements in sophisticated digital twin technologies. Organizations that are forward-thinking and proactive in adopting this new approach to R&D testing are poised to gain a variety of strategic benefits, from enhanced efficiency and reduced costs to a minimized environmental footprint. By focusing on the necessary infrastructure and optimization strategies, these companies are not just adapting to change, they are shaping the future of innovation.

In the article “How Virtual Design Can Change the Future of Research and Development,” published in IEEE magazine, Randy Rozema, Director, Acoustics & Vibration Applications and Principal at ACS, discusses how organizations should be proactive in adopting these advanced design tools. The future of R&D testing is heading toward a greater focus on virtual analysis, enabling companies to design and refine products more quickly and efficiently.

One of the key tools for this shift is digital twin technologies. This powerful tool provides R&D teams with the ability to conduct numerous design variations and tests digitally. The most significant advantage of this is the dramatic reduction in the number of costly physical prototypes that need to be built. By running parallel digital simulations, companies can accelerate development cycles, saving a substantial amount of time and resources. This approach fosters collaboration between product engineering and testing teams by creating a shared, data-driven “single source of truth.” This understanding ensures that analyses are performed on calibrated models, leading to more accurate predictions and a solution reached with far fewer iterations, revolutionizing the process of R&D testing.

To succeed in this new environment, establishing an effective and robust infrastructure is key. The market for digital twin technologies is a testament to its potential, with projections forecasting its growth to $99.2 billion by 2029. This highlights the trend of R&D relying more heavily on virtual analysis. However, organizations must prepare for the challenges that come with this digital shift, particularly the influx of a massive volume of data that will be generated. A strong infrastructure, whether on-premises or in the cloud, is essential for processing and storing this information in a format that is easily accessible to all project stakeholders. This also requires a strong emphasis on cybersecurity, as digital twin technologies can be used to simulate and analyze potential threats in a controlled virtual environment. The availability of comprehensive software suites further streamlines this process, allowing companies to integrate physical test data into their virtual models, often starting with a 3D scan to replicate a physical structure or device.

As technology becomes increasingly sophisticated, the entire design process is moving away from a primary focus on physical R&D testing and toward a more efficient, virtual design approach. Organizations that are proactive and recognize the need to invest in advanced design tools will be the ones to lead their respective industries. Modern software is now capable of performing complex flow, sound, and structural analyses, which allows for more products to be designed and refined exclusively in a digital environment. By embracing these capabilities, companies can bring their digitalization efforts to the next level, ensuring they remain competitive and innovative in a rapidly changing world. This adoption of virtual design is not just a trend, it’s the future of R&D testing.

Read the full article here.