Assembly Process Validation

Perform virtual assembly validation on large 3D models


Assembly Validation Challenges

  • Assembly validation often starts late after the design is nearly complete.
  • Assembly issues that are found late cause rework.
  • Assembly issues that are found after production starts have even higher costs.
  • Design changes require even more validation.

Benefits of XVL for Assembly Validation

Converting heavy 3D CAD data to lightweight XVL and adding manufacturing process information enables you to visualize and validate the entire assembly process. In this way, you can perform virtual assembly validation in XVL without waiting for the completion of design and without prototypes.  Finding and fixing assembly problems early, before the design is complete, improves product quality, reduces the number of prototypes, reduces the time and cost of rework and shortens the lead time from development to production.


Assembly Validation Challenges

Assembly Validation Starts Late

Traditionally the production engineering department performs assembly validation on physical models after all the parts have been designed and prototyped. Therefore, the more time it takes for design and prototyping, the later the assembly validation starts. In order to reduce the development lead time, it’s critical to remove the delay and start assembly validation as early as possible.

Finding Assembly Issues Late Causes Rework

During assembly validation the production engineering department answers such questions as: "Can the parts be assembled properly in order", "Are there any interferences between parts or tools in the assembly process" and "Do the tools and jigs function properly?" If an assembly problem is found at this stage, fixing the issue usually requires a redesign and a new prototype. Needless to say, this rework is expensive and takes a lot of time.

Production Problems Cause Even More Rework

The situation is even worse if assembly problems are discovered after production begins. Such issues have the potential to stop production until a solution is designed, prototyped and tested, further delaying production and raising costs. On top of that is the cost or reworking or scrapping the partial products produced before the issue was discovered.

Design Changes Require Additional Validation

Even if a complete assembly validation is performed on the final released design, the challenges do not stop there. It is always possible that there will be last-minute design changes. When that happens, it’s necessary to perform additional assembly validation on the updated design. With increased pressure to get the new design into production, there may not be time to do a thorough analysis, especially it the assembly validation process is slow or cumbersome.


XVL Solves Assembly Validation Problems

Visualize the Assembly Process with XVL’s Multi-BOM Structure

XVL supports multiple bills of materials, so you can include manufacturing BOM (mBOM) and process data in addition to the original 3D CAD engineering (eBOM) structure. The BOMs can be cross-linked and associated with geometry and part data.


Data provided by: Toyota Motor Corporation


With XVL you can add process information to your 3D model without changing the engineering structure. This enables you to perform assembly validation on the model while it is still being designed. There is no need to wait for final release, or even for a complete model, to begin your assembly validation.


Data provided by: Toyota Motor Corporation


Use XVL to Perform Complete Assembly Validation

With XVL you can verify the assembly process steps, check for interference and clearance between parts, and even check jigs and tools – all without prototypes. In addition, you can use human mannequins to check the visibility and clearance of each operation.


Generate assembly issue reports, complete with 3D visualizations, as feedback to the designers. Then validate the updated design using XVL. By repeating this cycle over and over, you can improve design quality up front, even before the design is complete. A better quality design requires fewer prototypes, less rework, lower costs and faster lead time.

Don't Waste Your Reviews

With XVL, you don’t have to start each assembly validation from scratch. XVL can carry forward validation results from previous models into new versions. So when you find an issue, report it back to the designers, and receive an updated model, you have all of your previous work for reference. Instead of validating the entire model, you can focus on only what changed. This enables you to accelerate your validations and get to production even faster.



XVL Product Configuration for Assembly Validation

XVL Studio Series

  XVL Studio Pro XVL Studio Standard
Visualize the assembly process
Reduce mistakes in the field
Maintain your verified results
Perform detailed interference verification  
Check geometrical differences (before/after design change) XVL Studio Difference Check Option
Check operator's workability and safety XVL Studio Human Option

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