Presenting at CORE2026 – Andre Volpato

Q: What’s the topic you’re presenting on this year?

Andre: I’m presenting on how we use computer simulations, essentially a “digital twin”, to make sure new rail vehicles are completely safe before they hit the tracks. Industry safety standards require us to demonstrate what is happening in the tiny, coin-sized area where a moving train’s steel wheel meets the rail.

In the real world, you can’t easily stick a sensor under a speeding train to measure those hidden forces. To solve this, we use targeted physical tests to validate our digital simulation so that it behaves as close as possible to a real rail vehicle.

Q: Why did you choose this topic?

Andre: I wanted to demystify how multi-body dynamics (MBD) tools work and show operators, safety regulators, and delivery teams that simulation is not some mystical black box; it is an engineering tool based on real-world measurements that has great power to protect a project, not drag it on.

I also chose this topic because these simulation exercises can, at times, be treated as a last-minute exercise after the real vehicle is already built.

The danger in such a case is that if a hidden safety flaw is uncovered at a late stage, fixing it may require slow, expensive retrofits. Hence, by moving this simulation work to the very beginning of a project’s timeline, we completely flip the script, allowing optimisation of the vehicle’s design before manufacturing even begins.

Q:  What can attendees expect to learn from your presentation?

Andre: Attendees will walk away with three clear takeaways:

• De-risking the Project Timeline and Benefits of Simulation: A look at the project benefits of running computer simulations at the very beginning of a timeline rather than the end. Attendees will learn how early engineering certainty keeps budgets on track, avoids late-stage overhauls, and completely bypasses the expensive trap known as the “Compliance Cliff.”

• Understanding of Current Australian Standards: A simple breakdown of current Australian safety rules and why relying entirely on real-world track testing can leave blind spots. Attendees will see why advanced computer simulations are uniquely suited to satisfy these strict safety metrics.

• Building Trust in Virtual Vehicle Models: An inside look at how a “digital twin” is built and tuned. I’ll explain the process of matching virtual physics against selective real-world test results to ensure the model acts like the real thing.

Q:  Why is it important to the greater rail industry?

Andre: Simulated dynamic assessments are vital as they directly target rolling stock delivery risk and asset longevity. By moving simulation “upstream”, during early concept design phases, rail networks can build engineered certainty.

Furthermore, a physical track test only captures a vehicle on a specific day in specific conditions. A validated simulation model allows us to evaluate a virtual fleet across its entire lifecycle: evaluating worn profiles, deteriorated dampers, or extreme environmental friction changes. It shifts risk away from field test conditions/results to engineer predictable fleets.

Q:  What else are you excited to see at CORE or from the rail industry in general this year?

Andre: I’m really looking forward to seeing if and how other organisations are utilising simulation and advanced data analytics to assess track-vehicle interaction. I’m keen to hear about other great work happening in the Australian rail space around asset lifecycle management, modern maintenance, and system integration. The sharing of ideas between rolling stock specialists, track engineers, and regulators is always the best part of CORE.

Simulation is not some mystical black box; it is an engineering tool based on real-world measurements that has great power to protect a project.

Andre Volpato