3DEXPERIENCE PLM and Automotive Industry

Many companies in the Automotive and Aerospace industries use Dassault Systèmes’ 3DEXPERIENCE as their PLM (Product Lifecycle Management) platform.

In today’s fast-paced industries, companies need tools that go beyond basic design software. Dassault Systèmes developed a comprehensive suite of solutions that helps teams streamline design, engineering, manufacturing, simulation, and collaboration across industries like automotive, aerospace, industrial machinery, and consumer goods.

At the heart of this ecosystem is the 3DEXPERIENCE platform, which integrates all of Dassault’s flagship products into a unified environment.

With this platform, teams work from a single source of truth connecting design, engineering, and manufacturing workflows while managing data and making collaborative decisions in real time.

Figure 1: AI-generated image created with Microsoft Copilot showing an artistic rendering of Parts and Tools in an outline of a car.

Here’s a closer look at the key products that make up this powerful suite:

• CATIA – Leading CAD software for 3D design and modeling.
• DELMIA – Digital manufacturing and operations planning solution.
• ENOVIA – PLM platform for collaboration, data management, and process governance.
• SIMULIA – Advanced simulation suite for realistic product behavior prediction.
• SOLIDWORKS – Intuitive 3D CAD for mechanical design, serving mid-market engineering teams.

Together, these solutions, when integrated with 3DEXPERIENCE, allow companies to accelerate innovation, reduce errors, and optimize workflows, delivering products faster and more efficiently than ever before.

Figure 2: Image created using Microsoft power point referencing Dassault Systems brands.

Fastener Torque in Automotive Manufacturing

When it comes to assembling vehicles, torque isn’t just a number, it’s a critical force that keeps everything tight, safe, and road-ready.

In simple terms, torque measures the force engineers apply to bolts, screws, and other fasteners to generate the clamping pressure needed for safety, reliability, and structural integrity in mechanical assemblies. Several factors such as the components being joined, bolt size, quantity, material, and lubrication affect torque values. Engineers typically measure torque in foot-pounds (ft-lb) or Newton-meters (Nm) and apply it using a nut runner or a manual torque wrench in industrial manufacturing.

Torque=Force × Length

20 N force × 1 m lever.  Torque=20×1=20 N.m

10 N force × 2 m lever. Torque=10×2=20 N.m

Figure 3: AI-generated image created with Microsoft Copilot showing the relationship of Force, Distance and Torque.

When it comes to tightening bolts, most people assume that using a torque wrench ensures perfect consistency. Set the wrench, pull until it clicks, and you’re good—right? Not always.

The reality is that torque readings can vary significantly, even between two “identical” fasteners. Factors such as the type of fastener, the materials of both the bolt and the component it threads into, thread cleanliness, and lubrication (including the specific type of lubricant used) can cause torque values to fluctuate notably (for Example 20 to 35 %), even when using the exact same torque wrench setting. To handle these scenarios with precision, industry follows two torque strategies.

Target Torque

Not every bolt in a vehicle demands surgical precision. In fact, many fasteners—like wheel studs, water pump bolts, and countless others—are designed with a bit of forgiveness in mind. Their job is to be tight enough to hold things together, but not so tight that they cause damage. This is called “Target Torque”.

Target Torque + Angle

When engineers work with torque-to-yield (TTY) bolts—such as engine or suspension head bolts—they don’t just tighten them; they stretch them. These bolts enter an elastic state, providing consistent clamping force across critical components. Engineers first apply a pre-set torque using a standard torque wrench, bringing the bolt close to its yield point—just before it begins to stretch. Then, they use a torque angle gauge to rotate the bolt a specific number of degrees, typically 90° or up to 360°, pushing it past the yield threshold and inducing controlled stretch. This process ensures consistent preload without measuring bolt elongation directly and is known as the “Target Torque + Angle” strategy.

Residual Torque: At the very end of the production line, one last step plays a key role in ensuring product quality: checking residual torque. Tightening strategies confirm that a joint meets specifications, but only residual torque tells us how much of the applied preload actually remains inside the joint.

Two Main Strategies to Measure Residual Torque:

• Breakaway Method: The most common approach. A digital torque wrench adds torque until the screw just begins to move, recording the torque value at that instant.
• Loosen–Tighten Method: Ideal when there’s a risk of over-tightening or when dealing with large screws. The joint is loosened slightly, then retightened, and the torque is measured as it returns to its original position.

Smarter Tools for Smarter Testing

In the past, operators relied on markers to track screw positions during manual tests. Today, digital torque wrenches with built-in gyros make the process faster, safer, and easier.

In practice, the sequence looks like this for assembling an engine:

1. Torque to spec with a standard wrench
2. Run the engine briefly to warm up components
3. Let the engine cool and then re-torque
4. Apply the final angle using a torque angle gauge.
5. Measure residual torque. Ensure the quality standards are met

Figure 4: AI-generated image created with Microsoft Copilot showing a Torque Angle Gauge

This combination of torque and angle delivers precision where it matters most.

Keep in mind while non-stretch bolts may seem like the simpler option for engine bolts, they come with extra work. Because they don’t flex under load, they require re-torquing after several heat/cool cycles. Over time, you may also need to re-torque them again, usually every 30,000 to 70,000 miles, depending on the application. Stretch bolts, on the other hand, are designed to elongate slightly when tightened. This controlled stretch allows them to provide consistent and even clamping pressure, reducing the need for repeated adjustments. Once properly installed to the manufacturer’s specifications, they typically don’t need to be touched again. Please note that stretch bolts cannot be re-used as used bolts have already surpassed the yield threshold and would not provide the same clamping performance as a new bolt.

How do we handle Torque workflow in PLM/3DEXPERIENCE?

A custom 3DEXPERIENCE solution addresses these complexities by allowing engineers to define torque requirements in CATIA, linking them directly to specific parts and assemblies in the Engineering Bill of Materials (EBOM). These specifications are automatically propagated to the Manufacturing BOM (MBOM) and Bill of Process (BOP) in DELMIA.

From there, torque information flows seamlessly from PLM to an MES (Manufacturing Execution System). The MES executes factory production based on the BOM, DELMIA/3DEXPERIENCE work instructions (Detailed steps for assembling parts), and ERP (Enterprise Resource Planning) order information, ensuring accurate torque application, traceability, and efficient factory operations.

If you’re new to the concept of a Bill of Process, it defines the sequence of manufacturing operations, along with the resources, tools, and work instructions required to build a product on the factory floor.

Minimal Attributes/Properties for Torque definition to work

• Joint ID: A unique identifier used by design engineering to track specific joint instances. The Joint ID is created automatically by the system when the parent assembly is promoted to either Frozen or Release
• Characteristic of the Joint – You can specify the design characteristic of the joints and possible options include Significant, Critical, and Non-Critical.
  • Critical – Essential functionality; absence or failure blocks core business or system operations.
  • Significant – Important functionality; affects efficiency or quality but does not block core operations.
  • Non-Critical – Optional functionality; adds value or convenience but has minimal impact if unavailable.
• Torque Strategy
  • Target Torque: The specified target torque, along with its tolerance, will be applied to the fastener during the vehicle assembly process.
  • Target Torque and Angle: A torque strategy including Target Torque, Torque Tolerance, Target Angle, and Angle Tolerance will be applied to the fastener during the vehicle assembly process.

What are the Torque-specific attributes?

• Target Torque (N·m): The specified torque value to be applied.
• Torque Tolerance (N·m ±): The acceptable range above or below the target torque.
• Target Angle (°): The specified tightening angle after reaching the torque.
• Angle Tolerance (° ±): The allowable variation in tightening angle.
• Residual Torque Max (N·m): The maximum torque measured during verification.
• Residual Torque Min (N·m): The minimum torque measured during verification.

How’s it handled in 3DEXPERIENCE?

Understanding References vs. Instances in Product Design

In product lifecycle management (PLM), it’s crucial to distinguish between a reference and an instance when dealing with parts and assemblies. A reference is the master definition of a part — it holds the part number, description, material, and overall design. Think of it as what the part is. An instance is when that part gets used in an assembly or BOM. It defines how and where the part is used, including details like position, or orientation. Torque values are specific to the instance/usage of the fastener. In 3DEXPERIENCE, assemblies (BOMs) may be structured in a single or multilevel parent-child hierarchy depending on the BOM complexity.

For example: A particular bolt type may be used hundreds of times in a complex product.

• The design of the bolt is the reference and exists only once.
• Each usage of the bolt in the product is an instance.

Figure 5: Image created using Microsoft power point showing EBOM and relationship to Fastener instances.

In 3DExperience each instances have “Unique Relationship/Instance ID”. These relationship IDs can hold instance attributes. Each of the “Unique Instance ID” s (Relationship ID) holds the Torque Attributes. Attributes on “Unique Instance ID” s (Relationship ID) is configured using 3DExperience “Data Model Customization” application.

Figure 6: Image created using Microsoft power point showing Fastener instances and associated attributes.

Where do I see it in 3DExperience?

Instance attributes are displayed in the ‘Instance’ tab in 3DExperience Part Properties view. Keep in mind that the layout of the attribute display is controlled using 3DExperience attribute layout configurations.

Figure 7: 3DExperience part instance properties panel showing custom Torque attribute fields.

Configuration and Automations

In 3DEXPERIENCE, configurations and automations leverage EKL (Enterprise Knowledge Language), JPO (Java Program Object), and OOTB (Out of the Box) setups to automatically generate Joint IDs based on defined conditions, propagate torque values across revisions, and manage Torque fields editability.

Programming Languages involved

• EKL (Enterprise Knowledge Language)
• OOTB (Out of the Box) configuration
• JPO (Java Program Object), and OOTB APIs (Application Programming Interface)

How does Torque data flows from EBOMà MBOM à BOPàMES?

DELMIA PPR = the digital backbone of manufacturing in 3DEXPERIENCE, connecting Product (what to build), Process (how to build), and Resources (with what to build, the tools, fixtures and even people employed in the manufacturing process).

Figure 8: Image from Dassault Systemes’ Manufacturing Product-Process-Resource Data Structure.

Maintaining EBOM–MBOM–BOP Traceability in 3DEXPERIENCE/DELMIA

Maintaining traceability between engineering and manufacturing data is critical to maintain the 3DExperience data model. 3DExperience maintains traceability and links between EBOM, MBOM and BOP using the Scope Link and Implemented Link concept.  To assign EBOM parts to MBOM, we must first establish a scope link between EBOM and MBOM. Once the Scope Link is established, we can then assign EBOM parts into MBOM. These part assignments are maintained using “Implemented Links”.

Scope Link: Establishing the Foundation

“Scope Link” tells the system: This is the source EBOM used to create the MBOM. Likewise, when you work with the Bill of Process (BOP), you must scope the MBOM with the BOP. This action defines the MBOM as the source that builds the BOP part assignments.

Implemented Link: Assigning Parts

Once the Scope Link is in place, Implemented Links are used to assign EBOM parts to MBOM. There is a one-to-one connection between EBOM Engineering Part instance to MBOM part. These connections are achieved with an” Implemented Link”. Similarly, the BOP will maintain Implemented Links with associated MBOM parts.

By leveraging Scope and Implemented Links, 3DEXPERIENCE/DELMIA provides a robust framework for managing product data across its lifecycle. Both Scope Link and Implemented Links are traversable using 3DExperience APIs.

Figure 9: Definitions of “Scope Link” and “Implemented Link”.

Figure 10: PPR structure showing the Scope Links.

Understanding Scope Links and Implemented Links in 3DEXPERIENCE

Figure 11: EBOM MBOM and BOP with Scope and Implemented Links.

End to End DATA Flow

Engineers use Manufacturing Execution Systems (MES) to digitally manage and monitor the entire production process, giving them real-time visibility and control over the plant floor to improve quality, efficiency, and compliance.

Here’s how MES leverages this data to ensure quality and compliance:

• Work Instructions: Provides operators with exact torque values and tightening sequences.
• Process Control: Automatically verify that torque tools meet specified parameters.
• Data Capture: Records actual torque values during assembly for traceability and audits.
• Alerts & Feedback: Detects incorrect torque application and triggers corrective actions.

Now that we have Engineering torque data authored in the EBOM, linked to the corresponding MBOM part and BOP Operations. This data needs to flow to MES to provide the information needed to assemble the product (vehicle). This data flow is achieved using an integration between PLM to MES. The integration process transfers all required BOM, BOP, and torque data directly to MES. It’s important to remember that integration scopes vary depending on each company’s unique needs.

Figure 12: Image from Dassault Systemes Manufacturing Product-Process-Resource Data Structure showing the integration data flow to ERP and MES.

How is Integration achieved?

3DExperience supports robust integration connectivity via RESTful APIs and event-driven messaging. Bi-directional integrations enable seamless data exchange between PLM, ERP (Enterprise Resource Planning) E.g. SAP, and MES ensuring complete workflow continuity and traceability. Below is the 3DExperience Integration architecture.

Figure 13: Image from Dassault Systemes Openness Technical Architecture showing 3DEXPERIENCEintegration architecture.

Summary
This article explains how 3DEXPERIENCE PLM and DELMIA enable end-to-end torque management in automotive manufacturing. It covers torque strategies, key attributes, and the seamless flow of data from EBOM to MES, ensuring traceability, process control, and real-time integration across PLM, ERP, and MES systems. I hope this will help you to solve the torque complexities in the PLM world.

Glossary of Terms

• PLM – Product Lifecycle Management
• EBOM – Engineering Bill of Materials
• MBOM – Manufacturing Bill of Materials
• BOP – Bill of Process
• ERP – Enterprise Resource Planning
• MES – Manufacturing Execution System
• PPR – Product, Process, Resource (DELMIA terminology)
• RESTful Web Service – Representational State Transfer Web Service; a web service architecture that uses standard HTTP methods for communication

• Author
• Recent Posts

Sijil Augustine

PLM 3DEXPERIENCE Product Owner at a leading automotive company in California, USA.

Sijil is a PLM expert with over 18 years of experience, specializing in implementation, customization, upgrades, data migration, and cross-platform enterprise application integration. His expertise spans across the Automotive, Medical, and Oil & Gas industries. Currently, he serves as the PLM 3DEXPERIENCE Product Owner at a leading automotive company in California, USA.

Latest posts by Sijil Augustine (see all)

• End-to-End Torque Management in Automotive Manufacturing with 3DEXPERIENCE PLM and DELMIA - 12 October 2025