Case Study: HCL Technologies cuts development costs 40% and reduces paper jams with Dassault Systèmes' Abaqus FEA

Designing Your Way Out of a Paper Jam with Realistic Simulation

HCL Technologies faced the persistent engineering challenge of designing reliable paper paths for high-speed printers—preventing skewing, buckling and paper jams—while keeping customization and development costs under control. To tackle this, HCL used Abaqus FEA from Dassault Systemes (SIMULIA) to simulate contact, material behavior and dynamic paper-roller interactions early in the design cycle.

Using Dassault Systemes’ Abaqus FEA for virtual prototyping, HCL’s engineers iterated designs, optimized roller and guide geometry, and validated results against physical prototypes. The simulations correlated well with reality and delivered measurable impact: about a 40% reduction in product development costs on average and roughly three months shaved off the typical A4 printer design-and-validation timeline.

HCL Technologies

Thangavel Mayilvaganan

Associate Project Manager