Are you wondering which interaction type should be used in SOLIDWORKS Simulation to represent a weld or to attach two bodies so they do not separate during the analysis?

Think about a bracket supporting critical components of a product. What must be done to ensure that the simulation accurately represents the real behavior before running the analysis?

After reading this blog, you will be familiar with the key steps required to properly define bonded interactions in SOLIDWORKS Simulation. 

Representation of the bonded interaction

In SOLIDWORKS Simulation, a bonded interaction is used to connect two or more bodies so that no relative motion is allowed at their interface. A typical example is welding a bracket to another component to reinforce a structure and reduce stress in critical areas.

A bonded interaction is equivalent to merging bodies while still allowing each part to retain its own material properties. Once defined, the connected bodies are assumed to never separate during the analysis. This represents an idealized, perfectly rigid weld. While such a condition does not exist in reality, it is often a reasonable and efficient assumption when a near-perfect weld behavior is expected.

A bonded interaction should not be used to represent a contact condition (formerly called No Penetration) or any situation where sliding between components is expected.

In some cases, however, it may be acceptable to use a bonded interaction instead of defining multiple contact conditions in order to simplify the analysis. An example is a threaded rod, where detailed local behavior is not required and where the objective is to capture the global structural response rather than local stresses.

Mesh refinement plays a key role in obtaining accurate results near bonded interaction regions. Adjusting the global mesh parameters or applying local mesh controls can significantly improve mesh consistency at the interface and help ensure reliable and meaningful results.

Modeling Assumptions: Using Bonded Interactions in a Welded Structure

We are going to consider the following case study to illustrate the bonded interaction application. See the image below:

In this jib crane case study, the gusset parts are welded to the column and base plate to increase the overall resistance of the local area. Because of the nature of the problem, we make the assumption that the parts are tied together and that there is no relative motion between them. Therefore, we can apply a bonded interaction at this location to represent multiple welding interactions.

Please note that it is not necessary to model the weld as a separate part or body in SOLIDWORKS. This simplifies both the model and the analyst’s work while requiring only minimal additional information.

As with any modeling assumption, the use of bonded interactions should always be aligned with the objectives of the analysis and the level of accuracy required.

Global vs Local Bonded Interactions: Setup and Best Practices

Here we are, the most sought after section of this blog on how to define the bonded interaction. There are several ways to define bonded interactions in SOLIDWORKS Simulation. The good news is that the default option when creating a stress analysis with SOLIDWORKS Simulation is set to apply a bonded interaction at a global level. This means that for coincident solid bodies, no additional interaction definition is required as long as the global interaction type is set to Bonded. The global bonded interaction can be found in the Simulation Tree in the Connections folder, under Component Interactions. Additional options can be set to take into account a gap between the bodies. The following image shows a case where a bonded interaction already defined by default could already be sufficient, meaning that there is no additional required step:

In some specific cases, a bonded interaction must be defined at a local level which requires a definition in the software. It could be the case of parts with different mesh types or geometry inconsistencies. Let’s consider the case study where there is a small gap between the gusset and the column where a bonded interaction is needed to represent a welding.

To define a local bonded interaction:

1. In the Simulation Tree, right-click Connections and select Local Interaction.

2. In Type, choose Bonded.

3. In the blue selection box, select the first entity (ideally the smaller one).

4. In the pink selection box, select the second entity (ideally the larger one).

5. Multiple entities can be selected if required.

6. If necessary, define additional options such as the gap tolerance.

Interpreting Results When Using Bonded Interactions

When the calculations complete and that we are at the step of validating the results, it is very important to understand how they should be interpreted. Adding unnecessary bonded interactions tends to artificially increase the stiffness of the structure. This can make the model appear stronger than it actually is, resulting in a non-conservative analysis. Therefore, it is important to keep that in mind and make sure that the analysis represents the real case study appropriately. An animation of the results is an excellent way to determine whether or not the structure behaves as it should be. Expect stress concentrations near edges with bonded interactions and pay attention to stress singularities. If necessary, plot the reaction forces and compare them with the applied loads. If the results don’t make sense, it is important to consider reviewing the analysis setup and rerunning the analysis.

Key Takeaways on Bonded Interactions in SOLIDWORKS Simulation

In this blog, we explored the application of bonded interactions to better understand their meaning and areas of use.

Through the lifting jib crane case study, we illustrated the creation of both global and local bonded interactions. In Finite Element Analysis (FEA), the quality of results depends primarily on the relevance of your modeling assumptions and choices.

Beyond interactions, there are other features that must be used properly to produce reliable simulations tailored to your objectives. If you wish to deepen your knowledge of SOLIDWORKS Simulation, several resources are available to support your progress.

You can visit our website to read our other technical blogs and learn more: https://www.solidxperts.com/en/blog/

Backing up your data is always a smart move. The good news is that the 3DEXPERIENCE platform already includes secure cloud storage, but sometimes you may want to create a local, on-site backup as well.

To help you do that, this guide walks you through two options:

1. Exporting one project at a time (top-level assembly in its own .zip file)

2. Exporting everything together (all data in a single .zip file)

Option 1: Export a Single Project

This method is perfect if you only need to back up a specific assembly or project.

1.Use the search field at the top of your session (or the Bookmark Editor, if you’ve bookmarked the file) to locate your top-level assembly.

2. Select the assembly (it will highlight in blue when chosen).

3. Click the chevron (arrow) to the right of the file.

4. Choose Export As.

5. Continue with the export steps outlined in the final section of this guide.

Option 2: Export Everything at Once

Heads up: If you have a large dataset, this method can produce a very large zip file. For performance reasons, we often recommend Option 1,  exporting project by project.

But if you do want the full export, here’s how:

1.Open the Bookmark Editor app.

• Create a new bookmark called something intuitive, like Export All Data.
• Leave Bookmark Editor open with your new bookmark selected.

2. In the search bar, type “prd” (default naming convention).

• If your company uses a different convention, use the keyword that applies to your setup (e.g. SX- for Solidxperts).

3. Optionally, refine results with 6W Tags (Who, What, Where, etc.).

4. Select all search results.

• Use the checkbox at the top of the list.
• Double-check the counter to ensure all items are selected. (If numbers don’t match, scroll to the bottom and re-select.)

5. Drag the selected files into your export bookmark.

• This applies the bookmark to all selected items.
• If you have a lot of files, give the system time to process.

6. Back in Bookmark Editor, group-select the files you want to export (Ctrl+A for all).

7. Click the 3 dots (⋮) in the upper right → choose Export As.

8. In the Export As dialog:

• Give your .zip file a clear title.
• Optionally, check Include Drawing.
• Confirm the item count. If it looks low, scroll to the bottom of Bookmark Editor to refresh, then try again.
• Review any exclusions in red . These could be xApp-created files (like xDesign) that aren’t currently exportable.

9. The system creates an export job.

• You can monitor large jobs in the CAD Data Processor Monitoring app.
• Smaller jobs often finish before they appear there.

10. Once complete, you’ll see a notification in the 3DNotification Center.

11. Click the notification, then hit Download to retrieve your .zip file.

Pro tip: Test the process with a small dataset first so you’re comfortable before running a full export.

Wrapping Up

Ultimately, with just a few steps, you can create local backups of your 3DEXPERIENCE projects, whether it’s one assembly at a time or your entire dataset.

Beyond the backup process, at Solidxperts, we help teams like yours work more confidently with 3DEXPERIENCE every day. If you’d like hands-on training or tailored backup strategies, our experts are here to guide you.

At Dassault Systèmes, keeping your account secure is a top priority. That’s why two-factor authentication (2FA) is now required when you access the DSx Client system.

What does this mean for you? In short: an extra layer of protection for sensitive data like user information and serial numbers. It also means a quick setup process the first time you log in and after that, peace of mind knowing your account is more secure.

This guide will walk you through:

1. How to set up 2FA on your phone (most common method).

2. How to set up 2FA on your computer using KeePassXC if you prefer not to use a mobile device.

Option 1: Setting Up 2FA on Your Phone

1. Download an Authenticator App

If you don’t already have one, install an authenticator app such as Google Authenticator, Microsoft Authenticator, or Okta.

2. Log in to Your DS Account

Sign in with your DS username and password.

3. Open the 2FA Setup Wizard

From your account, click My Profile > 2-Factor Authentication.

4. Activate 2FA

Select Activate to begin setup.

5. Set Recovery Options

Answer the required security questions. These will be used if you ever lose access to your 2FA device.

6. Connect Your Authenticator

In your authenticator app, choose Scan a QR Code (or Enter a setup key if your phone has no camera). Scan the code provided by Dassault Systèmes.

7. Test and Confirm

Your authenticator will display a 6-digit code. Enter it into DSx Client to confirm setup. Once successful, you’ll see a confirmation window — 2FA is now enabled! 🎉

Going forward: Every time you log into DSx Client, you’ll be asked for a code from your authenticator app.

Option 2: Setting Up 2FA on Your Computer (KeePassXC)

Prefer not to use your phone? No problem. You can configure 2FA directly on your computer with KeePassXC, a secure, open-source password manager.

1. Download and Install KeePassXC

Available for Windows, macOS, and Linux at KeePassXC’s website. Default installation options work fine.

2.Create a Database

This is where your passwords and tokens are stored. Set a strong master password and keep it in a safe place.

3.Add a DSx Client Entry

Create a new entry with:

• Title: DSx Client
• Username, Password
• URL: https://dsxclient.3ds.com

4. Set Up the 2FA Key

Right-click your new entry > Setup TOTP. Enter the secret key provided in DSx Client (same as in the phone setup).

5. Test and Confirm

Click the clock icon next to your entry to generate a 6-digit code. Enter it in DSx Client. Once confirmed, your 2FA is ready to go.

Wrapping Up

That’s it! You’ve now secured your DSx Client account with two-factor authentication. Whether you chose to set it up on your phone or on your computer, you’re adding an important layer of protection to your Dassault Systèmes tools.

And remember, if you hit a bump along the way, the Solidxperts team is always here to help. Reach out to us, and we’ll make sure your account stays safe and your workflow stays smooth.

A few weeks ago, my SOLIDWORKS Elite Applications Engineer award fell, and the top part of it broke. I was both sad and frustrated. Sad because it meant something to me, and frustrated because I had placed it on a shelf that later tilted unexpectedly, sending everything crashing to the floor. Finding it broken on the ground that day was tough.

Accidents like this happen all the time. The products we design are also at risk of being dropped, so why not make them as resistant as possible?

That’s exactly where SOLIDWORKS Simulation drop tests come in.

In this guide, you’ll learn:

• what a drop test is,
• why drop test analysis is essential for product reliability,
• and how to run a drop test in SOLIDWORKS Simulation step by step.

Why Drop Tests Matter for Product Design?

Any time a product is handled, shipped, carried, or installed, there’s a chance it could be dropped. A single impact can compromise safety, durability, performance, and sometimes even a company’s reputation.

Drop tests help engineers predict how their products will behave in real-world accident scenarios. Below are examples of industries where drop testing is essential to ensure reliability before manufacturing:

• Consumer products & electronics
• Industrial & heavy equipment
• Medical devices
• Sports equipment
• Aerospace & aviation
• Automotive & transportation
• Military & defense
• Packaging & logistics
• Robotics & automation
• Construction & civil engineering

Drop Test Prerequisites: What You Need Before Running a Simulation

Before running a drop test analysis, certain elements must be prepared. A 3D design is required to simulate the event digitally. Here are the steps:

1. Create the 3D model in SOLIDWORKS or import an existing geometry.
2. Apply materials (this step can also be performed directly in the study).
3. Simplify the model to reduce solving time (this may include suppressing non-critical parts or features).

How to Run a Drop Test Analysis in SOLIDWORKS Simulation

Once your model is ready, you can set up the drop test using the following steps:

1. Enable the SOLIDWORKS Simulation add-in.
2. Create a new Drop Test study.
3. Apply any missing material properties.
4. Define interactions if needed.
5. Set up the drop test conditions (drop height or impact velocity, orientation, ground parameters, etc.).
6. Adjust result options (duration after impact, saving options, etc.).
7. Mesh the model and run the analysis.

Interpreting Your Drop Test Results

After running the analysis, several result types become available, such as stress and deformation plots. These help you determine whether the product will remain elastic, undergo plastic deformation, or potentially fail, and where such failures are likely to occur.

The example below shows the kind of output SOLIDWORKS Simulation provides once the calculations are complete:

Improving the Design Through Simulation

Thanks to the results, you can identify weak points where the product is likely to fail. You can then reinforce the design. For example, by adding fillets, increasing wall thickness, or selecting a stronger material.

Sometimes, results show that a part is overdesigned. In these cases, you may reduce thickness or remove unnecessary material to lower weight and cost. This is a key step in optimizing your product.

Simply make the changes and re-run the drop test to validate the improvements.

Bringing It All Together: Stronger Designs Through Simulation

With SOLIDWORKS Simulation, you can test your product digitally long before manufacturing it. A drop test is just one of many analysis types available to help you validate performance and reliability.

I initially blamed myself for the broken award, but maybe if the shelf had been designed to be stronger, the accident could have been avoided. Who knows?

From linear static to nonlinear dynamic analyses, SOLIDWORKS Simulation provides a complete suite of tools to help engineers validate their designs efficiently. At Solidxperts, we are committed to helping our customers achieve excellence in their engineering projects.

Looking to sharpen your skills? Browse our upcoming trainings, available at our offices or online. Whether you’re new to simulation or ready to deepen your expertise, our certified specialists are here to support you every step of the way.