The paradox of traditional commissioning
Imagine constructing a building: the architect designs the structure, the electrical engineer plans the wiring, and the plumbing contractor develops the utility networks, but each works independently without coordinating with the others. Only when the building is completed does it become apparent that cable trays do not fit where expected, systems interfere with structural elements, and electrical outlets do not match switch locations.
In industrial environments, this same scenario plays out whenever mechanical designers, electrical engineers, and PLC programmers work in separate silos and only come together, often too late, during the commissioning phase. The result is a bottleneck that can account for 25–30% of the total development time of an automated machine.
It is precisely this paradox that Siemens NX Mechatronics Concept Designer (MCD) aims to solve, transforming the traditional sequential approach into a parallel, multidisciplinary workflow.
What is NX MCD?
NX MCD is a mechatronic simulation environment integrated within the Siemens NX platform. To understand it through a simple analogy, think of it as a flight simulator for industrial machinery: instead of limiting itself to the 3D design of a component, MCD adds operational intelligence to the CAD model through virtual sensors, actuators, kinematics, collision detection, gravity, and control logic, enabling the machine to “operate” on screen exactly as it will on the shop floor.
The difference compared to traditional CAD is significant.
A conventional CAD project answers the question: “What does this machine look like?”
An MCD project answers the question: “How does this machine behave?”
The gap between these two questions, measured in engineering hours and correction costs, can be worth hundreds of thousands of euros on every complex project.
Three industries, three challenges, one approach
Automotive: Simulating the entire assembly line
A manufacturer of automated packaging machinery used MCD to create a digital twin of a production line and validate its dynamic behaviour before physical construction.
Conveyors, actuators, sensors, and motion control logic were simulated within a single environment, making it possible to verify operating sequences, cycle times, and safety conditions during the early stages of development.
Before adopting MCD, many issues would only emerge during machine commissioning, when mechanical modifications or control software changes were expensive and required weeks of additional work. By leveraging mechatronic simulation and virtual PLC integration, the team was able to test and optimise automation logic in advance, significantly reducing debugging activities and accelerating final commissioning.
Pharmaceutical: Packaging designed for regulatory compliance
A blister packaging machine for a European pharmaceutical company was designed entirely within the MCD environment, simulating servo-axis behaviour, dosing cycles, weighing controls, and reject systems.
The result was a 40% reduction in validation time, a critical advantage in an industry where every post-installation change requires a new IQ/OQ/PQ qualification cycle.
Aerospace: Multidisciplinary collaboration on one-of-a-kind projects
In the aerospace sector, where each special machine tool is often a unique build, MCD enabled engineering teams to explore dozens of “what-if” scenarios during the conceptual design phase, identifying integration issues that would otherwise have surfaced months later.
The benefit is not only financial. It represents a dramatic reduction in overall project risk.
The core value proposition: virtual commissioning
Virtual commissioning is where MCD delivers its greatest strategic value.
By connecting the virtual model directly to a real or emulated PLC through native integration with TIA Portal, automation engineers can test, debug, and refine control programs without waiting for the physical machine to be assembled.
According to project evidence, this practice can reduce commissioning time by 50–70%.
The cost of correcting an error in a virtual environment is effectively close to zero. Correcting that same issue on a physical machine, involving specialised personnel, machine downtime, and the risk of equipment damage, can cost orders of magnitude more.
A bridge to Italy’s Transition 4.0 Plan and the National Recovery and Resilience Plan (PNRR)
For Italian companies, NX MCD fits squarely within the scope of investments eligible under the Transition 4.0 Plan.
Mechatronic simulation and virtual commissioning software solutions fall within the category of Industry 4.0 intangible assets covered by Annex B of the legislation. Furthermore, starting in 2024, the new Transition 5.0 tax credit includes enhanced incentives for investments that reduce energy consumption. The ability to virtually optimise machine cycles and servo motor energy usage aligns directly with these objectives.
NX MCD is not simply “another software package” added to an NX license.
It represents a fundamental organisational shift: enabling mechanical, electrical, and automation engineering teams to work in parallel on a shared functional model, reducing iterative cycles, eliminating surprises during assembly, and bringing better machines to market faster.
For machine builders, this translates into protected margins and stronger competitiveness in international projects.
