Risk-Based Digital Mock-Up Validation for Full-Vehicle Routing

Digital Mock-Up (DMU) validation plays a critical role in automotive product development by enabling early assessment of vehicle packaging and routing systems. However, conventional DMU workflows rely primarily on geometric clash detection and may overlook functional routing risks such as positional deviation, attachment support deficiencies, CAD inconsistencies, thermal proximity, abrasion potential, and serviceability constraints. This study presents a methodology-driven, risk-based DMU validation framework for full-vehicle routing assessment using Siemens VisMockUp. The proposed framework integrates multiple routing-risk domains within a structured Risk Priority Number (RPN) methodology derived from Failure Modes and Effects Analysis (FMEA) to support consistent issue classification, prioritization, and corrective-action planning. The framework was applied to representative routing review scenarios across multiple vehicle packaging zones. Comparative engineering observations indicate that the proposed approach may reduce false-positive issue escalation, improve the identification of critical routing conditions, and enhance routing-review efficiency compared with conventional clash-focused practices. These observations are presented as illustrative engineering estimates and are not intended as statistically validated experimental results. The proposed framework provides a systematic methodology for multi-domain routing-risk assessment that supports engineering decision-making, early-stage design validation, and improved digital product development workflows.