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Linear vs. Nonlinear Simulation: What’s the Difference?

Written by | Prableen Sachdeva
June 11, 2025
| 8:50 am
When running structural simulations in SOLIDWORKS, one of the most important decisions you’ll make is choosing linear or nonlinear analysis. While they might sound like variations of the same concept, they solve very different kinds of engineering problems. In this blog, we’ll break down what each method does, how they differ, and when to use each one.

What is a Linear Simulation?

A linear static simulation assumes a straight-line (or linear) relationship between forces and displacements. This is the most commonly used type of analysis in SOLIDWORKS Simulation.

It makes the following assumptions:

  • Small deformations (geometry doesn’t change much under load)
  • Material behaviour is linear (stress is directly proportional to strain)
  • Loads and boundary conditions remain constant throughout the analysis

Ideal User Cases:

  • Brackets, enclosures, and sheet metal under small loads
  • Elastic materials that aren’t pushed near their yield point
  • First-pass design validation to quickly identify stress concentrations

What is a Nonlinear Simulation? A nonlinear simulation considers real-world complexities where assumptions of linearity break down. This includes:
  1. Material nonlinearity: like plastic deformation, rubbery materials, or hyperelasticity
  2. Geometric nonlinearity: large deformations that change part shape during loading
  3. Contact nonlinearity: where parts come into or out of contact (ex., Snap fits or crush zones)
Nonlinear problems are solved incrementally over time, making them computationally heavier but far more realistic for complex scenarios. Ideal Use Cases:
  • Rubber gaskets, silicone seals, or soft-touch plastics
  • Snap-fit assemblies or components under large deflections
  • Metal parts under loads close to (or beyond) yield
  • Crash, impact, or buckling simulations

How to Know Which One to Use

Here’s a quick decision guide:

Question Go Linear If… Go Nonlinear If…
Are deformations small? Yes No
Is the material staying elastic? Yes No(ex., plastic or rubber)
Are you modeling contact or separation between parts? No Yes
Do you need a quick approximation? Yes No
Is speed a priority over accuracy? Yes No

If you’re unsure, start with a linear analysis. If the results seem unrealistic (ex., too much displacement, high stress in flexible materials, or parts “passing through” each other), it’s a sign to go nonlinear.

Pro Tip: Use Both

Many engineers start with a linear simulation for quick insights, then refine the analysis with nonlinear when:

  • Material properties become a factor
  • There’s evidence of large displacement
  • Assembly behaviour involves contact or separation

This approach balances speed and realism, especially during iterative design.

Choosing between linear and nonlinear simulation in SOLIDWORKS isn’t just about the software – it’s about understanding how your product behaves in the real world.

If your design is simple, stiff, and elastic? Linear is probably all you need.

If you’re dealing with complex interactions, flexible materials, or extreme conditions? Nonlinear is the way to go.

Need help deciding which method is right for your specific project? Reach out to our team of experts and they’d be happy to help.

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