The durability group is engaged in every step of the product development cycle from load case development, analysis, test correlation and finishing with signoff. Our engineers have expertise in performing complex analyses while applying real-world experience to multiple industries, including autonomous vehicle, commercial truck, entertainment, aerospace, oil and gas, and consumer product.

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Load Case Development

Our CAE team defines analysis strategies based on customer duty cycles or usage plans. The load cases developed cover all pertinent aspects of the product life cycle including abuse and fatigue scenarios.


Assessing strength is one of the important requirements for establishing product performance and understanding potential failure modes. We perform a variety of strength analyses to help design components for mechanical, acceleration, thermal and pressure loads, ranging from large military vehicles to precision machine tools.

Contact Stress

Our analysis team tackles highly complex contact stress and fatigue problems involving gears, rollers, and Hertzian contact. We exercise various contact algorithms including penalty functions or Lagrange multipliers to accurately predict contact stresses.

Assembly Stress

We have extensive experience in providing analysis support for Design for Assembly (DFA) while accounting for statistical variation. We perform all methods of assembly analysis including joint clamping, clevis closure, riveting, interference fits, and gap tolerance.

Non-Linear Elastoplastic Analysis

We are proficient in analyzing the behavior of structures due to material or geometric non-linearity, strain rates and temperature effects. Hood and door slam, curb push-off, stone hit, and component drop test are just a few examples where we use this analysis technique.

Buckling Analysis

For load bearing structures, buckling from compressive loading is a concern. Our team has extensive experience with linear eigenvalue analysis as well as non-linear analysis to accurately capture effects of imperfections, plasticity and large deformation. We have experience in predicting snap-through buckling as well as post-buckling behavior.

Static Fatigue

Our durability group performs fatigue analysis using stress-life or strain-life to predict the durability life of chassis, body, powertrain, interior or electronic components. We have experience with analyzing for low and high cycle fatigue life, incorporating surface treatment and surface roughness effects.

Vibration Fatigue

We have extensive experience in analyzing structural assemblies under random vibration (PSD) and harmonic input. We develop software tools to predict fatigue life for a given random vibration fatigue profile. Our team is adept at creating random vibration loadcases using acceleration data obtained in physical tests.

Transient Fatigue

Our engineers use force-time histories to replicate operating conditions including the effect of structural resonances. Increased accuracy from this approach reduces testing time and cost while improving likelihood of success.

Accelerated Durability

Our engineers interpret and modify road load data (RLD) or any other duty cycle to develop equivalent damage in accelerated lab tests. We have successfully implemented these techniques to reduce development time and cost for our customers.

Seismic Loading

For large, static structures, seismic loading could be of importance depending on the geographical location of installation. Our engineers calculate structural response from seismic loading to ensure that the structural integrity is maintained.

Thermo-Mechanical Stress

Using a multi-disciplinary approach, we utilize thermal maps generated by our computational fluid dynamics (CFD) team to perform thermomechanical stress analysis. We have effectively applied this expertise for powertrain, exhaust and boiler structures.

Aero-Induced Loading

Roush CFD and durability teams work in close coordination to transfer data across their domains. Our multi-physics team has extensive experience performing these analyses on external components like spoilers and hoods for racing and performance applications.

Drop Analysis

Whether it is dropping a cell phone or airdropping a military vehicle, our team can predict the effect from any scenario. Our engineers also help our customers in characterizing the complex material behavior involved in these situations through material coupon testing.


We use topology and topography optimization tools to reduce component cost and weight while adhering to structural requirements. Various load conditions are considered while incorporating manufacturing constraints in the optimization process.

Design Verification (DV)

Our durability group provides test coordination support to optimally position sensors and instrumentation. Our expertise with real-world structural behavior and analytical simulation minimizes test cost while maximizing the utility and accuracy of the measured data.

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