KiCad Finite Element Analysis (FEA) with free Software Tools from Udemy

This course is for you if you already use KiCad but either cannot or choose not to invest in a commercial FEM tool.

Beyond learning how to perform FEM (and FDTD) simulations with free tools, you will also discover fascinating insights that will undoubtedly make you a better hardware design engineer by the end of this course.

By the end of this course, you'll have a solid foundation in using free FEM tools for PCB design, empowering you to make better design decisions.

What You Will Learn

In this course, I will guide you through simulating the following topics using free software tools for KiCad:

Current Flow in PCB Traces (DC) / PDN analysis / PI analysis
- Learn how to simulate the current flowing through a PCB trace.
- Based on current density, we will analyze and simulate voltage drops along the trace.
- This will in return also give you information about the trace resistances
Electric Fields Around Traces and Components
- Understand how to simulate electric fields around traces and components.
- Explore 3D field simulations to visualize signal propagation and identify areas where PCB routing can be improved.
- We will simulate static electric fields with the free tool Elmerfem and dynamic electromagnetic fields with OpenEMS.
Troubleshooting
- I will show you many ways to troubleshoot typical errors when working with the free tools which will hopefully lead to a fast learning curve.

What's inside

Learning objectives

Learn to use the finite element method (fem) / finite element analysis (fea) / finite element modelling method (femm) for kicad with free tools
Simulate the dynamic electromagnetic or static electric fields around your kicad traces
Simulate the voltage drop and current distribution of your traces (pdn/pi analysis)

Fem / fea simulations can nicely suplement your ltspice simulation results
Lean how to use the free tools kicad, elmergui, openems, freecad, gmsh, paraview, ... to create 3d simulations

Learn to use the finite element method (fem) / finite element analysis (fea) / finite element modelling method (femm) for kicad with free tools
Simulate the dynamic electromagnetic or static electric fields around your kicad traces
Simulate the voltage drop and current distribution of your traces (pdn/pi analysis)
Fem / fea simulations can nicely suplement your ltspice simulation results
Lean how to use the free tools kicad, elmergui, openems, freecad, gmsh, paraview, ... to create 3d simulations

Syllabus

This Section will show you some of the simulations that we will perform in this course

Preview Electric Field Simulation around a Microstrip

Preview Heat conduction from copper trace to PCB

In this section, I will start uploading problems related to dynamic electromagnetic field simulations.

Since this section is new (created on December 19, 2024), it will take some time to populate it with content.

For those coming here from YouTube: About 50% of my Udemy students are seeing this content for the first time and haven't watched it on YouTube before. Therefore, I will also post many videos that are already available on YouTube. However, don’t worry—there will be exclusive lectures here that will remain available only on Udemy.

All the tools covered in this lecture can also be installed on Linux / Ubuntu.

Although I haven’t yet recorded a video tutorial for the installation process, I can confirm that the entire workflow runs smoothly on Linux (at least on Ubuntu). I’ve tested it successfully across several Ubuntu versions.

Please install the following tools on Linux / Ubuntu:
KiCad 9 (for PCB design)

FreeCAD (to edit the PCB’s 3D data)
Salome (to generate a mesh from the 3D data)
ElmerFEM (to run FEM simulations)
ParaView (to visualize simulation results)
LibreOffice (spreadsheet editor)
Optional: GMSH (an alternative meshing tool that can be used instead of Salome)
If you are unsure how to install applications on Ubuntu / Linux, refer to Lecture 6. It demonstrates the installation of KiCad, FreeCAD, and ParaView. Using the same approach, you should be able to install the remaining tools once needed.

The next lectures of this section (Section 4) are still done with KiCad 6 as I did not find time yet to update them. If you want to keep using KiCad 9, you will have to slightly adapt your workflow.

The main difference between KiCad 6 and 9 is, that KiCad 6 was not able to export 3D step data and instead the 3D files were created with a FreeCad plugin and some python commands.

With KiCad 9 you can export the 3D model of the PCB right away from the PCB editor.

ground bounce and current flow distribution of an Arduino Board to find out where the ground layer needs improvement.

Learn how to fix errors when trying to create meshes from KiCad ground planes

In this lecture, we will revisit the simulation from the previous session, but this time we'll utilize the latest versions of KiCad and FreeCAD (as of December 10, 2024). Additionally, we'll replace Salome with GMSH for this process.

This approach offers an alternative workflow for the simulation. If you're satisfied with the method covered in the previous lecture, feel free to skip this video.

Career center

Learners who complete KiCad Finite Element Analysis (FEA) with free Software Tools will develop knowledge and skills that may be useful to these careers:

Signal Integrity Engineer

A Signal Integrity Engineer is crucial for ensuring high-speed digital and analog signals travel reliably across printed circuit boards. This role involves analyzing signal reflections, crosstalk, impedance matching, and power delivery network performance to prevent data corruption and ensure system stability. This course is exceptionally well-suited for aspiring Signal Integrity Engineers, as it provides a robust foundation in using free Finite Element Analysis tools for detailed PCB design analysis. Learners will practice simulating dynamic electromagnetic fields around traces, conducting trace impedance analysis, and optimizing decoupling capacitor placement. The ability to visualize signal propagation and identify potential routing improvements within KiCad using tools like OpenEMS directly translates into the core competencies of this specialized and critical engineering discipline.

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Power Integrity Engineer

A Power Integrity Engineer focuses on ensuring a stable and clean power delivery network (PDN) for electronic devices, preventing voltage drops, ground bounce, and noise that can degrade performance. This professional diagnoses and mitigates issues related to current distribution and voltage stability on printed circuit boards. This course offers an excellent pathway into this specialized field, equipping learners with practical skills in conducting PDN and PI analysis using free software tools for KiCad. You will learn to simulate current flow in PCB traces, analyze voltage drops, and understand trace resistances. The detailed instruction on identifying current hotspots, optimizing power plane designs, and troubleshooting common simulation errors directly supports the essential functions of a Power Integrity Engineer, enabling more robust and reliable designs.

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Electromagnetic Compatibility Engineer

An Electromagnetic Compatibility Engineer ensures that electronic systems operate correctly in their intended environment without generating or being susceptible to electromagnetic interference. This involves anticipating and mitigating issues like crosstalk, radiation, and susceptibility, ensuring products comply with rigorous regulatory standards. This course offers highly relevant skills for an Electromagnetic Compatibility Engineer. With its focus on simulating dynamic electromagnetic fields, wave propagation, and crosstalk in KiCad designs using tools like OpenEMS, you gain direct experience in analyzing and improving the electromagnetic behavior of PCBs. The ability to identify areas for improved PCB routing and understand field distributions is crucial for designing EM-compliant hardware.

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Electronics Design Engineer

An Electronics Design Engineer is responsible for the conception, design, and development of electronic circuits and systems, often specializing in printed circuit board layouts. This role requires a deep understanding of component selection, schematic capture, and layout principles, with a strong emphasis on ensuring functionality, performance, and manufacturability. This course is invaluable for an aspiring Electronics Design Engineer, as it directly addresses a critical aspect of modern hardware development: leveraging simulations to make informed design decisions. By learning to perform FEM and FDTD simulations for current flow, electric fields, and thermal characteristics within your KiCad designs, you will gain insights that undoubtedly enhance your design prowess, leading to more reliable and optimized electronic products.

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Modeling and Simulation Engineer

A Modeling and Simulation Engineer develops and utilizes computational models and simulation software to predict the behavior, performance, and reliability of complex physical systems or processes. This role is fundamental across various engineering disciplines, requiring expertise in numerical methods and simulation tools. This course is exceptionally well-aligned for an aspiring Modeling and Simulation Engineer. It focuses entirely on applying Finite Element Analysis (FEA) and Finite Difference Time Domain (FDTD) methods using free software tools. Learners gain hands-on experience with a suite of simulation tools like ElmerFEM, OpenEMS, FreeCAD, GMSH, and ParaView. This practical exposure to setting up, running, and interpreting complex electromagnetic, current flow, and thermal simulations on KiCad designs provides a strong foundation for a career that often requires an advanced degree in a relevant engineering or scientific field.

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Applications Engineer

An Applications Engineer acts as a technical expert, assisting customers with the implementation and optimal use of complex software tools or hardware products. In the context of electronic design automation (EDA), this involves demonstrating software capabilities, troubleshooting user issues, and developing custom solutions. This course provides highly relevant expertise for an aspiring Applications Engineer specializing in EDA tools. By mastering free FEM tools like KiCad, ElmerGUI, OpenEMS, FreeCAD, GMSH, and ParaView, you develop a deep, practical understanding of their functionality and common pitfalls. The course's emphasis on troubleshooting typical errors and preparing layouts for maximum compatibility directly equips you to support other engineers effectively in their simulation efforts, making you an invaluable resource.

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Hardware Engineer

A Hardware Engineer designs, develops, and tests physical components of computer systems and electronic devices, from microprocessors to circuit boards. This role involves a blend of electrical engineering principles, system architecture, and often embedded software considerations, aiming to create functional, efficient, and reliable hardware. For aspiring Hardware Engineers, this course offers a distinct advantage by honing skills in advanced PCB analysis using simulation. It moves beyond basic design to provide deep insights into the physical behavior of electronic components and traces within KiCad. You will learn to predict and mitigate issues like voltage drops, electromagnetic interference, and thermal hotspots, which are critical for robust hardware development, thereby improving overall product performance and longevity.

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RF Engineer

An RF Engineer specializes in the design, development, and testing of devices and systems that operate in the radio frequency spectrum, often including antennas, transceivers, and high-frequency circuit boards. This role demands a strong grasp of electromagnetic theory and wave propagation. This course can be highly beneficial for an RF Engineer, particularly in the context of high-frequency PCB design. By learning to perform FDTD simulations with OpenEMS and analyze dynamic electromagnetic fields around KiCad traces, you gain practical skills in understanding wave propagation and impedance characteristics at RF frequencies. The ability to simulate current distribution over frequency and analyze trace impedance via S11 analysis is pivotal for optimizing high-frequency circuit performance, complementing design efforts effectively.

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PCB Layout Engineer

A PCB Layout Engineer translates electrical schematics into physical printed circuit board designs, considering signal integrity, power distribution, thermal management, and manufacturing constraints. This role requires meticulous attention to detail and a strong understanding of how physical layout impacts electrical performance. This course can significantly elevate the capabilities of a PCB Layout Engineer. While focusing on layout, the course empowers you to proactively identify and resolve potential issues through advanced simulation. Learning to perform FEM simulations for current flow, electric fields, and thermal behavior within KiCad allows you to optimize trace routing, component placement, and power/ground plane design, leading to more robust, high-performance, and reliable PCB layouts, thus making better design decisions before fabrication.

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Thermal Design Engineer

A Thermal Design Engineer focuses on managing heat dissipation in electronic systems to ensure optimal performance, reliability, and longevity of components. This involves analyzing heat flow paths, identifying hotspots, and designing effective cooling solutions for printed circuit boards and enclosures. This course offers specific and valuable training for a Thermal Design Engineer, with a dedicated section on performing thermal simulations of KiCad layouts. You will learn to simulate heat conduction from copper traces to the PCB, analyze multi-material thermal behavior, and define thermal resistances. The practical application of ElmerFEM to model heat transfer coefficients and natural convection directly empowers you to make informed decisions about component placement and trace design to prevent overheating and ensure thermal stability in electronic products.

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Research Engineer

A Research Engineer explores new scientific principles and engineering technologies, often developing innovative solutions or advancing existing methodologies. This role typically involves a blend of theoretical understanding, experimental design, and advanced computational analysis. This course may be useful for a Research Engineer, especially one focusing on electronic design and analysis. While research roles often require an advanced degree, the course provides practical skills in advanced simulation techniques like FEM and FDTD using free tools. Learning to simulate complex electromagnetic phenomena, current distribution, and thermal effects on KiCad designs can be instrumental for investigating novel PCB materials, high-speed design challenges, or developing new analysis workflows, supporting experimental work or theoretical exploration.

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Design Verification Engineer

A Design Verification Engineer is responsible for verifying that a complex electronic design, such as an integrated circuit or a printed circuit board, meets its specified functional and performance requirements. This involves creating test plans, developing testbenches, and running simulations to identify design flaws. This course may be helpful for a Design Verification Engineer, especially in hardware-focused verification. While typically associated with higher-level digital logic verification, the course provides critical skills for physical layer verification. Learning to perform FEM and FDTD simulations on KiCad designs to analyze signal integrity, power integrity, and electromagnetic behavior allows for the verification of physical design constraints and performance criteria, ensuring the hardware behaves as intended before costly fabrication.

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Product Design Engineer

A Product Design Engineer is involved in the entire lifecycle of a product, from conception and ideation to detailed design, prototyping, and preparing for manufacturing. This role blends aesthetics, ergonomics, and engineering functionality, often requiring a multidisciplinary approach. This course may be useful for a Product Design Engineer whose products involve complex electronics. The ability to perform advanced simulations of PCB performance—covering current flow, electric fields, and thermal management within KiCad—allows for a more holistic and robust product development process. These skills facilitate better design decisions, ensuring the electronic heart of a product is reliable and efficient, ultimately leading to higher quality and more successful product launches.

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Reliability Engineer

A Reliability Engineer focuses on predicting, preventing, and managing failures in products, systems, and processes, ensuring they perform as expected for their intended lifespan. This role often involves statistical analysis, failure mode and effects analysis, and understanding environmental stressors. This course may be useful for a Reliability Engineer working with electronic hardware. By enabling detailed simulation of critical PCB characteristics such as current flow, voltage drops, and thermal behavior using free tools, learners can identify potential stress points or failure mechanisms early in the design cycle. Understanding how electromagnetic fields interact with components or how heat conducts through materials, using KiCad, directly contributes to designing more reliable electronic products and reducing future field failures.

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Systems Engineer

A Systems Engineer approaches complex projects holistically, integrating various engineering disciplines to design, develop, and manage entire systems over their lifecycle. This role bridges hardware, software, and operational aspects, focusing on overall system performance and reliability. This course may be helpful for a Systems Engineer, particularly those involved in hardware-intensive systems. While not directly about system architecture, understanding the detailed electrical, electromagnetic, and thermal behavior of printed circuit boards through advanced simulation can significantly inform system-level design decisions. The ability to predict potential hardware issues with KiCad designs, such as signal integrity problems or thermal hotspots before integration, contributes directly to building more robust and reliable overall systems.

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