Simulation Has Been Transforming Industries for Decades – Now It’s Here for Roll-to-Roll
- Published: January 16, 2025
For decades, simulation has been a competitive advantage in industries like automotive and aerospace. Engineers use virtual models to explore designs, test “what-if” scenarios, and understand complex system behavior before building physical equipment. Today, that same simulation-driven approach is reshaping how R2R and web converting systems are designed and optimized.
Web handling is inherently dynamic. Tension, speed, material properties, and control systems all interact, and small changes can have system-wide effects. Simulation helps teams manage that complexity by revealing how the entire line behaves, not just individual components in isolation.
Saving time and money is just the first step
At a basic level, simulation significantly reduces the need for costly, time-consuming physical testing. Running trials on production equipment requires machine availability, technician time, and often leads to scrap and material waste. Those realities limit how many ideas can realistically be explored.
With simulation, engineers can evaluate web lines, materials, operating conditions, and control strategies virtually. Tests that once took hours can often be completed in minutes, without interrupting production.
Going beyond: empowering the organization
Simulation does more than save time and money - it changes how organizations work. Full-color visualization of tension propagation across a web line gives teams a shared, system-level understanding of performance. Engineers, controls specialists, and leadership can review design changes together, discuss trade-offs using common data, and make decisions with greater confidence.
Simulation also helps capture expertise. In web handling, practical knowledge is often built over years of working on machines. Digital models preserve design intent and system behavior, creating a durable knowledge base that can be reused and improved over time. New engineers can safely experiment and see how changes in layout or automation affect tension across the machine, accelerating learning and improving consistency.
When simulation becomes part of daily workflows, it strengthens collaboration, encourages experimentation, and supports a culture of innovation.
Simulation is essential – and MapleSim delivers it
As web converting systems grow more complex, simulation is no longer optional. MapleSim for Web Converting Systems is designed specifically to deliver system-level insight, combining web dynamics, mechanical components, and control logic in a single, physics-based environment.
Customers use MapleSim to transform how they design, validate, and optimize web lines – accelerating development, improving performance, and reducing risk before capital is committed.
Proven across industries, backed by experience
Maplesoft works with companies across printing, packaging, battery production, and other web-based industries where precision and reliability are critical. With years of expertise in system-level modeling and strong partnership with industry leaders, Maplesoft provides not just software, but the engineering support needed to apply simulation effectively.
Getting started with simulation
Our experienced simulation specialists would be happy to discuss your converting or web handling project, and suggest ways simulation may be useful to your R2R system.
For more information visit www.maplesoft.com/rolltoroll or contact Adison Edwards at This email address is being protected from spambots. You need JavaScript enabled to view it. (direct 1-919-749-3470).
