The Hidden Costs of CAE Complexity

A restraint system must protect all occupants—men, women, children, the elderly, and heavier individuals. Achieving that universality is a daunting task. A system that performs perfectly for a mid-sized male may become unsafe for a smaller female or a child.

Design, simulation, and validation cycles are often slowed by inefficiencies and rework. CAE engineers must constantly explain their results to non-CAE stakeholders—vehicle safety managers, test leads, or executives—who may not easily interpret injury metrics. This communication gap leads to repeated decision loops and further delays.

Meanwhile, the lack of diagnostic clarity forces senior experts to spend hours guiding junior engineers rather than improving methods. If key experts are unavailable, project timelines stall.

The question for today’s engineering leaders becomes unavoidable:
What if you could automatically identify which part of the restraint system contributed most to an injury metric—and understand how to fix it?
That’s the shift from reactive troubleshooting to predictive insight.

This is where Humanetics’ INSIGHT CONNECT® redefines the process. Built for both restraint and safety simulation engineers, INSIGHT CONNECT® automates root-cause discovery in occupant safety analysis—helping teams pinpoint the why behind dummy injury overshoots in minutes instead of days.

Its strength lies in automated force-vector visualization, a powerful diagnostic feature that maps how crash forces move through the dummy and restraint system. Engineers can instantly see which body regions or components drive injury peaks—and understand precisely how to correct them.

Measured Impact: 

• Up to 56 days saved per vehicle program through automation.
• 50–60% time savings across design–simulation–test loops.
• Up to 96 days of total engineering effort reduced for a four-person safety team.
• 21 additional days saved by avoiding false root-cause tracing.

By eliminating guesswork and enabling clear, data-driven decisions, INSIGHT CONNECT® gives teams back control over both time and technical confidence – helping them move from reactive troubleshooting to proactive engineering. 

Safety simulation has outgrown its silos. Engineers validating airbag deployment, restraint interaction, or full-vehicle crash performance all need a common language of causality. INSIGHT CONNECT® provides exactly that.

Fully aligned with emerging NCAP Virtual Testing (VT) standards, the platform helps teams meet future requirements without increasing cost or effort. It identifies whether an injury overshoot stems from a single component—such as a pretensioner—or a complex interaction between multiple restraint elements.

By quantifying load paths and showing how forces act on each body segment, the platform bridges technical and managerial discussions. Engineers gain rapid diagnostic confidence, while decision-makers gain clarity they can act on.

In practice, this unified visibility turns CAE results into actionable narratives—accelerating internal approvals, shortening iteration loops, and ensuring compliance confidence long before physical testing begins.