Industry Survey Reveals Adoption Success and Critical Barriers Ahead 

Manufacturing process simulation has historically been underused in the composites industry compared to structural performance modeling, but is now gaining significant traction. Composites are essential to both reducing fuel consumption in conventional vehicles and offsetting battery weight in electric vehicles to maintain efficiency and range. As these drivers accelerate composite part counts across automotive and aerospace sectors, manufacturing simulation’s ability to considerably accelerate part development times positions it front and centre to the industry practice changes that must follow.

In 2024 NAFEMS commissioned a comprehensive survey of industry professionals across the global composites sector. The objective was to establish a clear baseline of current practices, quantify the barriers limiting progress, and formulate propositions that will enable the industry to meet the demands ahead. The findings reveal both substantial progress in simulation adoption and specific capability gaps that must be addressed to handle the coming scale-up in production volumes and development cycle acceleration that competitive pressures demand.

The survey was designed to capture a snapshot of where we are: quantifying adoption patterns, identifying barriers, and helping us understand how organizations currently structure their simulation capabilities. The findings provide the foundation for evidence-based recommendations that can guide the industry through this transition.

This article appeared in the April 2026 Issue of BENCHMARK.