How Virtual Prototyping Accelerates Vehicle Development

Sustainability has rapidly moved from a strategic consideration to a defining priority for nearly every industry. Nowhere is this more evident than in the automotive sector, where manufacturers face increasing expectations from governments, cities, investors, and consumers to meet ambitious zero-emission goals. Today’s citizens aren’t just looking for vehicles that get them from point A to point B — they expect mobility solutions that are environmentally responsible, ethically produced, and developed with long-term planetary health in mind. This shift toward sustainability is often referred to as “Mission Zero,” signaling the commitment to eliminating waste, emissions, and inefficiencies across the entire product lifecycle.

This whitepaper examines how Keysight CAE is partnering with leading automakers to accelerate progress toward Mission Zero by transforming how vehicles are imagined, engineered, validated, and brought to market. Instead of relying on isolated numerical simulations and costly, resource-intensive prototypes, Keysight enables organizations to move toward 100% Virtual Prototyping. In this approach, every stage of development — from concept and design to manufacturing, assembly, and validation — is conducted in a fully digital environment.

The impact of this shift is profound. Virtual Prototyping dramatically reduces the need for physical materials, test vehicles, and energy-intensive trial-and-error cycles. At the same time, it increases agility, enhances safety, and creates opportunities to prioritize human well-being in both product design and workplace operations. By successfully implementing sustainable practices in the virtual world first, automakers can scale them confidently in the real world — minimizing risk while maximizing environmental benefit.

This whitepaper brings these concepts to life with compelling real-world examples. A French OEM recently launched a new vehicle with only a single regulatory physical crash test — yet still achieved a five-star Euro NCAP rating. Another automaker removed physical prototype testing entirely during a battery program bidding process, evaluating performance and reliability using only a Virtual Prototype. And during the global pandemic, when physical collaboration was restricted, a German manufacturer continued development in an immersive digital environment and shortened its development cycle by nearly 10 months.

These milestones were not accidents — they represent a disruptive but deliberate shift away from historical dependence on physical trials. The paper explores how leading OEMs successfully overcame organizational, technical, and operational barriers to adopt virtual-first methodologies. It also breaks down the key simulation capabilities required to enable this transition at scale, particularly in the high-stakes area of vehicle safety.

Readers will gain insight into:

• Why Mission Zero is reshaping product development across the industry
• How Virtual Prototyping eliminates waste and emissions while improving outcomes
• Real examples of OEM success stories
• The role of simulation in replacing physical tests
• The path toward safer, faster, more sustainable innovation

Ultimately, this whitepaper demonstrates that Virtual Prototyping is not simply a technical upgrade — it is a strategic enabler for the sustainable automotive enterprise of the future. As the industry accelerates toward zero emissions, manufacturers that can design, test, and validate entirely in the digital world will lead the way — reducing environmental impact while continuing to deliver safe, innovative vehicles to market.