Systems thinking in Design and Simulation
What if the biggest obstacle to better products isn’t the technology—but the way we think about using it?
Over the past few decades, we’ve replaced pencils with pixels, and physical prototypes with virtual models. On paper, it looks like we’ve evolved. But in practice, many teams are still following a playbook written years ago—just faster and with shinier tools.
The real opportunity today isn’t just in digitizing the old process. It’s in reimagining it entirely.
In this post, we’ll explore how blending disciplines, shifting mindsets, and rethinking the design-to-delivery cycle can unlock smarter products, leaner processes, and better results—both in performance and in profitability.
Key themes:
- Cradle-to-grave thinking
- Bringing simulation into the design phase earlier
- Trying more, failing less
Innovation in 2025 shouldn’t look like it did in 1995. Sure, we’ve made progress—from drafting tables to CAD, from physical prototypes to virtual testing—but in many ways, we’re still following the same old process, just with fancier tools. Designers design, manufacturers build, and customers use. That linear model hasn’t changed much.
But it could—and probably should. With affordable computing power, advanced software, and AI becoming more accessible, we now have an opportunity to rethink the whole approach. It’s not just about doing things faster or virtually—it’s about rethinking what we’re trying to achieve and how we get there.
Start with the full lifecycle in mind
Cradle-to-grave thinking means considering the full journey of a product from the very beginning. Who’s going to use it? How will it be maintained? What happens to it at the end of its life? Those questions should be part of the design process, not afterthoughts.
We also need to look at emerging materials and manufacturing methods—and ask which traditional ones may no longer make sense, whether because of cost, availability, or environmental impact. Sometimes doing better by doing good (like designing for reuse, recycling, or refurbishment) isn’t just the ethical choice—it’s also good for the bottom line.
Simulate early, simulate often
As systems become more complex—mechanical, electrical, software all intertwined—integrating simulation early can open up new design possibilities. It allows teams to explore multiple directions before locking into a single approach, reducing the risk of major redesigns later. It’s not just about checking if something works—it’s about discovering what could work even better.
One-shot design choices don’t cut it anymore
The old “build it, break it, fix it” mindset often leads to suboptimal outcomes, especially when time and budgets are tight. But those constraints are usually based on narrow, short-term thinking. If we start budgeting with the entire product lifecycle in mind, we might find that building something more repairable or more reliable actually lowers total cost of ownership—and improves long-term profitability.
Of course, none of this happens overnight. Real change requires both the ability and the willingness to do things differently. That means involving everyone—designers, manufacturers, vendors, even customers—and treating them like true partners in the process. Vendors, for instance, can offer valuable insights if brought into the conversation early enough.
It may also help to bring in external experts who specialize in digital transformation or systems thinking. These perspectives can accelerate the shift from a traditional siloed model to something more integrated and forward-thinking.At TotalSim, we’ve helped companies across many industries take steps toward building more connected, adaptive, and digital design ecosystems. If you’re ready to bring more systems thinking into your development process—or just want to explore what that might look like—feel free to reach out to us at info@totalsim.us.