Strategies and Methods for Recreating the Operating Behavior of a Technological Object Through Virtual Prototyping Based on an Optimized Initial Design

Abstract

Virtual prototyping is one of the most significant enablers of accelerated product development, allowing engineers to predict and validate system behavior under realistic operating conditions before physical realization. However, the behavioral gap between optimized initial design models and true working-condition performance remains major limitation due to multi-physics coupling,
embedded control interaction, parameter uncertainty, and manufacturing variability. This paper presents an expanded review of strategies and methods for recreating operational behavior through virtual prototyping. Key approaches include multi-domain modeling, reduced-order techniques, co-simulation frameworks, model calibration, uncertainty quantification, and virtual commissioning. A structured workflow is proposed, progressing from optimized CAD/CAE models toward validated behavioral virtual prototypes capable of supporting life-cycle digital twin evolution. Two tables and an architectural figure concept are included to support submission-ready presentation.