Insight Connect

A digital platform where CAE engineers upload simulation files to analyze crash events, view force impacts on virtual dummies, and enhance automotive safety.

Project type: End-to-end web application

Role: UX designer (reported to Mary Gombas , Senior Product Designer, Humanetics)

Industry: Industrial Technology, Safety Equipment, Simulation Software, Sensor Technology

Tools: Figma, Microsoft Teams

Duration: Q4 2023 - Q4 2024

Problem Statement

CAE engineers struggle to extract meaningful insights from crash simulation data due to fragmented workflows, lack of intuitive visualization, and inefficient analysis tools, making it difficult to optimize safety systems effectively.

Empathize

Understanding the Users and Context

Objective: Understand the workflows, pain points, and expectations of CAE (Computer-Aided Engineering) analysts.

Insight Connect legacy visualization tool

Screenshot of legacy visualization tool

Activities Done:

Engaged with safety engineers and CAE experts to understand current workflows using LS-DYNA and traditional physical dummy testing
Observed users interacting with legacy simulation software tools and spreadsheets.

Observations:

File formats (d3plot, binout, d3hsp) were not user-friendly in older tools.
Manual cross-checking of forces and injury criteria was time-consuming.
Users wanted seamless visualization of complex data.

Define

Identifying the Core Problem

Objective: Clearly articulate the problem based on user needs and insights.

Problem Statement:

CAE engineers face challenges in deriving actionable insights from crash simulation data due to disjointed workflows, limited visualization capabilities, and inefficient analysis tools hindering their ability to optimize vehicle safety systems effectively.

Design Goals:

Streamline file upload and model rendering.
Provide intuitive time-based visualization of forces.
Enable clear project management with version control.
Improve the discoverability and interpretation of force metrics.

Ideate

Exploring Possible Solutions

Objective: Explore a wide range of ideas to solve the defined problem.

User flow

Ideation Techniques Used:

Ideation sessions with CAE analysts and product managers to brainstorm interface flows.
Mapped flows for Creating a project, Uploading simulation files and Visualizing results (3D dummy + force graphs)
Created multiple visual designs in Figma showing file upload process, timeline based force charts and 3D dummy views

Key Ideas Explored:

Timeline scrubber to review force progression
Explored interaction patterns for effectively engaging with complex 3D models
Hover-based info tooltips on 3D model
Auto-generation of force vs time graphs for each dummy part
Exportable reports for authorities

Prototype

Designing the Solution

Objective: Create interactive versions of the application to test key functionalities and user interactions.

High-fidelity Mockups

Key Screens Designed:

Login & Dashboard with project overview tiles
Project creation flow with file upload process
3D Visualization Panel with real-time rendering of dummies using simulation data
Dynamic and interactive charts in Force Charts Panel
Annotation & Export Tools for engineers to document insights

Design Elements:

Clear information hierarchy
Minimal, clutter-free UI for ease of use
Icons, colors, and layouts that align with CAE activities

Test

Validating the Experience

Objective: Validate assumptions, discover usability issues, and iterate based on feedback.

Testing Activities:

Conducted multiple testing rounds with CAE engineers
Used scenario-based tasks (e.g., “Upload a crash simulation and analyze chest acceleration”).

Findings and Iterations:

Users loved the 3D model + chart sync.
Needed better error messages for unsupported file formats.
Included filters for multiple incidents comparison
Wanted quicker load times for large simulations.
Improved chart filtering and exporting UX.

Impact & Takeaways

Results:

30% faster analysis time compared to legacy tools.
Improved accuracy in identifying cause of injury/failure using event timeline
Received positive feedback from field testers

What I Learned:

Understood the importance of cross-functional collaboration between designers, engineers, and product teams in a highly technical domain.
Learned how to translate complex simulation data into clear, visual, actionable insights.

Final Thoughts

Designing Insight Connect was a deep dive into simplifying complex crash simulation workflows for CAE engineers. Using the Design Thinking approach, we transformed fragmented processes into a seamless experience with intuitive 3D interactions, timeline scrubbers, and clear data visualization.

This project highlighted the power of user-centered design in technical domains and opened doors for future enhancements like predictive analytics and real-time collaboration.