FlexSim – 3D simulation for production, logistics and digital twins

Introduction to the tool

FlexSim is a simulation software package for discrete-event simulation (DES) that combines modelling, analysis and visualisation in a realistic 3D environment. Models are built directly in 3D space using drag-and-drop and replicate the appearance and behaviour of the real-world system. This allows existing and planned production and logistics facilities to be analysed risk-free before changes are implemented in the real world.

The software combines ease of use with a high level of modelling depth: pre-built object libraries and drop-down lists enable rapid results without programming, whilst complex logic can be modelled using the Process Flow diagram tool or custom scripts. FlexSim has been further developed by Autodesk since November 2023 and is used worldwide by industrial companies, including numerous Fortune 500 firms.

Areas of application and typical use cases

FlexSim is used across a wide range of industries. Typical use cases include:

• Manufacturing and factory simulation: production lines, throughput analyses, bottleneck investigations
• Warehousing and intralogistics: material flow, conveyor systems, order picking and warehouse processes
• Supply chain simulation: analysis and validation of supply networks
• Healthcare: patient flows and processes in hospitals
• Specialised applications such as airport simulation
• Industry 4.0: digital twins and PLC emulation for validating control logic

Key features and strengths

FlexSim combines a high level of modelling depth with ease of use. An overview of the key features:

3D modelling

• Drag-and-drop model creation directly in the 3D view, with realistic visualisation
• Standard object library with pre-configured, customisable objects
• Process Flow: Logic as a flowchart using ready-made activity blocks, even for complex processes
• CAD import and 3-axis layout for precise spatial relationships and accurate travel times

Analysis and Optimisation

• Model real-world variations using a wide range of statistical distributions
• Dashboards, charts and statistical analyses
• Experimenter: calculate and compare multiple scenarios in parallel, including a reporting function
• Scenario optimisation with multiple objective functions via the integrated OptQuest engine

Integration and Extension

• FlexScript (C++-like), full C++ integration and a module SDK for custom components
• Data integration with existing systems, for example via a RESTful HTTPS API
• Direct import of CAD and BIM data from AutoCAD, Inventor and Revit
• Photorealistic collaboration on the digital twin: NVIDIA Omniverse (OpenUSD) and VR at the click of a button

Benefits for those new to simulation or digital twins

FlexSim offers practical benefits, particularly for users who are new to simulation:

• Quick model creation without programming knowledge, using drag-and-drop and predefined libraries
• Logic presented in a familiar flowchart format with Process Flow, rather than having to write code
• Free trial version for a risk-free start
• Comprehensive documentation with tutorials, videos and an active community (Autodesk forums, FlexSim Answers)
• Training, support and project guidance from SimPlan

Digital twins and PLC emulation with FlexSim

FlexSim is designed as ready-to-use standard software for digital twin applications. Its open architecture enables models to be built automatically from data. Robust database interfaces, a RESTful HTTPS API and a web server interface connect the model to real-world data sources, in real time if required. In addition, FlexSim supports AI and machine learning, including a tool for training reinforcement learning algorithms.

For the verification of control systems, FlexSim offers integrated PLC emulation: control logic can first be designed and tested in Process Flow, after which the actual PLC logic is validated against the model. Connections to OPC DA/UA tags, Modbus registers or Allen-Bradley tags are linked to the 3D objects in the model at the click of a button. In this way, FlexSim bridges the gap between process simulation and virtual commissioning.

Product family and versions

• FlexSim: the flagship product for 3D simulation, modelling and analysis
• Free trial version: available via Autodesk
• Offers for teaching and study: Educational Portal with offers for students and lecturers

Technical Fundamentals and Structure

• FlexScript scripting language (similar to C++) for extending individual model logic
• Open architecture with full C++ integration
• Object-oriented model structure comprising freely combinable, programmable 3D building blocks
• Windows-only application

Frequently Asked Questions (FAQ)

Who is FlexSim suitable for?

For companies in manufacturing and logistics that wish to validate and optimise plant layouts, material flows or processes, from the first simulation project right through to the digital twin.

Is programming knowledge required?

Not for many models. The object library, drop-down lists and Process Flow cover a large proportion of use cases. For more complex logic that goes beyond the standard features, FlexScript can be used, for example

Can I try FlexSim for free?

Yes, a free trial version is available via Autodesk. We’d be happy to help you get started.

Is FlexSim suitable for digital twins?

Yes. FlexSim models can read data at regular intervals or in real time, run simulations automatically and transfer results to other systems.

Can I integrate a DWG layout directly into FlexSim?

Yes, FlexSim supports the direct import of DWG and DXF files as true-to-scale model layouts. An automatic snap function ensures that objects such as conveyor belts or shelving align precisely with the lines in your CAD drawing. This allows you to incorporate real-world plant data directly into your simulation model without having to measure manually.

Manufacturer / Availability

FlexSim is manufactured by Autodesk. SimPlan is the distribution partner for Germany. SimPlan is available to assist anyone interested with enquiries regarding licences, projects or training. If required, we can provide support with your first model, through workshops or with complete simulation projects.