Case Study: Modine Manufacturing Company achieves $750K+ in development savings with ANSYS structural FEA

Pilot Structural FEA Program Unveils Substantial Savings

Modine Manufacturing Company, a long-established maker of automotive and off-road heat exchangers and climate control systems, needed to cut costly physical prototyping and speed up structural certification of complex components. Lacking dedicated structural FEA expertise, the New Product Development group sought a commercial finite element analysis solution to reduce design iterations, lower lifetime costs, and improve testing success—selecting ANSYS for the pilot.

ANSYS deployed a structural FEA pilot using ANSYS/Professional and ANSYS/Mechanical (with CADfix interoperability) in Modine’s Truck Division to screen design variations and perform linear and non‑linear analyses. The program certified an inlet air cooler tank in one pressure-cycle test after a single retooling, cutting development time by 12 weeks and avoiding about $18,000 for that part; across 12 projects in 18 months ANSYS-based simulation identified more than $750,000 in development cost avoidance while enabling designs to be optimized in only two iterations.

Modine Manufacturing Company

Bob DeGroot

Modine Manufacturing Company