Automotive manufacturers often rely on advanced computer simulations to test whether a component design will be strong enough and practical to produce. However, these simulations can be slow, expensive, and dependent on specialist expertise.
Through Innovate UK’s BridgeAI programme, Multi‑X Solutions Ltd developed and validated an AI-driven software solution for design validation with PAB Coventry, which demonstrated major time and cost savings while maintaining the accuracy of traditional engineering simulation.
The challenge
Automotive and aerospace manufacturers depend on Computer‑Aided Engineering (CAE) to test whether structural designs are manufacturable before they are physically produced. CAE simulations model how a component will be manufactured under real‑world conditions such as forming speed or temperature, helping engineers identify problems early and reduce costly rework later in the development process.
However, these simulation workflows can also create significant bottlenecks. Running detailed simulations often takes a long time, which can delay key design decisions. The process can be expensive, as it requires substantial computing power, and it typically depends on specialist engineers with highly specific expertise. In addition, many traditional tools focus primarily on how a component performs once it is in use, rather than on whether it is straightforward and economical to manufacture at the individual part level. This can leave manufacturers discovering production challenges later than they would like.
The solution
Multi‑X Solutions Ltd developed Multi‑X AI to address these challenges. The platform is a design‑for‑manufacturing software system driven by deep learning intended to accelerate the journey from initial design to production. In this case, AI is applied to engineering datasets to enable the system to rapidly predict outcomes that would normally require time‑consuming simulations.
Multi‑X AI is designed to optimise structural designs, enhance assessments of manufacturability, reduce the costs associated with repeated simulation cycles, and improve the speed of engineering validation. Unlike traditional CAE tools, which can require long compute times and specialist input, Multi‑X AI is able to deliver rapid outputs while maintaining accuracy comparable to established physics‑based simulations. Physics‑based simulations rely on mathematical equations that describe real‑world physical behaviour and are considered highly reliable, but they are also computationally intensive.
The platform also differs from some emerging AI tools in the market by focusing specifically on manufacturability at the vehicle‑part level, rather than concentrating solely on full‑vehicle performance. Support from BridgeAI enabled Multi‑X to tailor and fully train the system for PAB Coventry’s commercial use, refine the platform based on hands‑on industrial feedback, train PAB Coventry’s engineering team, and clearly define the unique selling points of the technology for wider industry uptake.
The impact
The results of the feasibility study were substantial. PAB Coventry reported an 80 percent reduction in simulation time when using Multi‑X AI compared with traditional approaches, alongside a 30 percent reduction in simulation spend. The AI system achieved accuracy comparable to physics‑based simulations while offering full remote accessibility, increasing flexibility and reducing reliance on local computing infrastructure.
The project also validated the technology for commercial use, and PAB Coventry committed to adopting Multi‑X AI within its operations. The project also helped Multi‑X secure a new customer and strengthened confidence in the product’s relevance to real industrial needs. As a further indicator of commercial readiness and growth potential, Multi‑X was accepted into the Carbon13 Venture Launchpad programme and CBIT Venture Builder programme.
The future
Following the successful feasibility study, Multi‑X Solutions Ltd plans to scale the platform for broader use across the automotive and aerospace manufacturing sectors. The validation of product‑market fit has strengthened the company’s ability to grow and deliver impact, supported by continued refinement of the technology and engagement with industry partners. Visibility through the BridgeAI programme has also helped position Multi‑X as a contributor to the adoption of artificial intelligence in UK manufacturing.
Multi‑X’s AI software platform is a promising technology. It is shaping up to be a strong asset. We believe this product aligns well with our business needs and will deliver significant value to our operations.
– Mark Brazier, CEO of PAB Coventry