Problem

Structures with bi-stable behavior are extremely sensitive to small geometric changes. Mapping out how geometry drives response by testing physical specimens alone is expensive and slow, and without a validated numerical model there's no quick way to know how a new design will behave before you print and test it.

Solution

Converted the idealized bistable-beam geometry into an FEA-ready parametric model that could be solved on a consistent basis. Built the FEA model to solve the nonlinear, large-deformation transient problem needed to capture the force-displacement curve. Extracted the reaction-force output mimicking the real experimental setup, processed it, and compared it directly against the physical test data.

Impact

The FE model matched the experimental force-displacement curves closely, which gives the team a validated way to predict bistable behavior, without the need to fabricate and test a new physical specimen for every design variant.