fleXstructures

What fleXstructures does

fleXstructures GmbH is a private German software company founded in May 2012 as a spin-off of the Fraunhofer Institute for Industrial Mathematics (ITWM) in Kaiserslautern, with a second office opened in Ingolstadt in 2024. It commercializes the IPS (Industrial Path Solutions) software suite, which performs real-time, physics-based simulation of flexible components — primarily cables, hoses, wiring harnesses, bellows, grommets, and flat cables — for the digital design, validation, and optimization of complex mechanical and electrical systems. The platform is modular: IPS Cable Simulation is the core engine, augmented by modules for durability and dynamics analysis, digital human modeling (IMMA), collision-free assembly path planning, robot optimization, virtual paint and sealing simulation, pointcloud integration, and virtual reality validation. Material property inputs come from MeSOMICS, a patented measuring machine developed with Fraunhofer ITWM.

The company serves primarily major automotive OEMs and Tier 1 wiring harness suppliers — including BMW, Volkswagen, Audi, Mercedes-Benz, Porsche, Volvo Cars, Stellantis, Toyota, Ford, Hyundai, Honda, LEONI, Yazaki, Coroplast, and Kromberg & Schubert — and has extended into construction machinery (John Deere, Komatsu, Kubota), rail and aerospace (Siemens Mobility, SAAB Aerospace), and electronics manufacturing (Sony Global Manufacturing). Reported outcomes include 75% faster robot commissioning and 25% improved cycle time on robotics programs.

Revenue is generated through a mix of software licensing for the IPS suite (with associated maintenance/support), professional engineering services including cable/hose measurement via MeSOMICS, and paid training through the IPS Academy ("fX Academy"). Go-to-market relies on direct enterprise field sales from the Kaiserslautern HQ for the DACH region, supported by wholly-owned subsidiaries in Italy (2018) and North America (2020, co-located with Sandalwood Engineering & Ergonomics), and a layer of regional distribution partners across Scandinavia (IPS AB), the UK (Centricity Consulting), Japan (SCSK), Korea (EMPIAS), China (Pan Information Technology, GLB, Hysim), and Taiwan (Hoyetek). The company is TISAX-certified for mobility-sector information security, and has been recognized with multiple regional innovation and Mittelstand awards between 2017 and 2019.

Name

fleXstructures

Legal name

fleXstructures GmbH

Website

https://flexstructures.com

Company type

Private

Founded year

2012

Operating status

Operating

Headcount range

11–50 employees

Short description

fleXstructures GmbH sells the IPS software suite for real-time physics-based simulation and validation of cables, hoses, and wiring harnesses, primarily serving automotive OEMs, Tier 1 suppliers, and increasingly construction machinery, rail, and aerospace manufacturers.

Ownership category

akta.pro rank

Product category

Engineering Simulation Software (CAE)

NAICS

Computer Systems Design and Related Services (54151)

SIC

Services-Computer Integrated Systems Design (7373)

akta.pro primary industry

Robot Software, Autonomy Stacks & Simulation (ROS, digital twins) (HDAAAIAK)

Keywords

• Cable simulation software
• Wiring harness design
• Robot path planning
• Flexible component simulation
• Automotive CAE software

Headquarters

HQ city

Kaiserslautern

HQ country

Germany

HQ region

Europe

Offices2 records

Markets served

GTM type

B2B

Offering type

Software

Cost components

Technology or R&D, Personnel, Marketing or Sales, Operations, Infrastructure

Revenue model

1. Software Licenses (IPS Product Suite): fleXstructures distributes the IPS software suite for cable simulation, robot optimization, and digital human modeling. Revenue is generated through software licensing, likely on a subscription or perpetual license basis with annual maintenance/support fees. The software is used by major automotive OEMs and suppliers globally.
2. Professional Services & Engineering: Engineering services including troubleshooting, customized engineering, measurement of cables and hoses using MeSOMICS, and method development. These customer-oriented projects are conducted by experienced specialist teams.
3. Training Services: IPS Academy provides software training including basic seminars, advanced training, and best practice sessions. Training is offered for beginners and expert users on a regular basis.

Pricing tiers

Go-to-market motion2 records

Distribution channels10 records

Marketing channels7 records

Core offering

fleXstructures develops and sells the IPS (Industrial Path Solutions) software suite for physics-based real-time simulation of flexible components including cables, hoses, wiring harnesses, bellows, grommets, and flat cables. The software enables design engineers in automotive, industrial machinery, railway, and aerospace industries to validate, optimize, and plan assembly of cable and hose systems virtually, reducing physical prototypes. The company also provides IPS Robot Optimization for offline robot programming, digital human modeling (IMMA) for assembly ergonomics, and professional engineering services including training and MeSOMICS material property measurement.

Product overview

fleXstructures offers the IPS (Industrial Path Solutions) Product Suite, a comprehensive software platform for 3D physics-based design, validation, and optimization of flexible components. The core product is IPS Cable Simulation, which simulates the real-time behavior of flexible cables, hoses, wiring harnesses, bellows, and grommets. The platform is modular, consisting of specialized modules including IPS Durability and Dynamics for dynamic analysis, IPS IMMA for digital human modeling and ergonomics evaluation, IPS Path Planner for automatic collision-free assembly/disassembly paths, IPS Robot Optimization for robotics commissioning, IPS Sealing & Adhesives and IPS Virtual Paint Spray for surface treatment simulation, IPS Pointcloud Tools for integrating scanned data, and IPS Virtual Reality for immersive validation. IPS fleX Hub serves as the online platform enabling the workflow. The suite also includes professional services such as IPS Training (webinars, basic and advanced sessions) and Engineering Services (troubleshooting, cable/hose measurement using MeSOMICS technology, and custom method development). The software targets automotive, construction machinery, rail vehicles, aviation, robotics, and electronics industries.

Differentiator

Problem solved

Functional benefit

Brands

• IPS (Industrial Path Solutions): IPS is a software suite based on innovative algorithms for virtual product realization, used for tasks ranging from flexible components design, assembly feasibility, robot optimization to simulation of complex flow and surface treatment processes. Products include IPS Cable Simulation, IPS Bellows & Grommets, IPS Flat Cables, IPS Durability and Dynamics, IPS IMMA, IPS Path Planner, IPS Pointcloud tools, IPS Robot Optimization, IPS Sealing & Adhesives, IPS Virtual Paint Spray, IPS Virtual Reality, and IPS fleX Hub.
• fX Academy

Products and services

• IPS Cable Simulation Software program for correctly simulating the behavior of flexible cables and hoses simultaneously, accurately, and in real time. Provides high-precision predictions and quality evaluation of flexible hoses and cables with motion. Used by automotive OEMs and suppliers for wiring harness engineering.
• IPS Bellows & Grommets and IPS Flat Cables Simulates flexible, moving bellows and grommets with fine structures using a fast FEM-based approach. IPS Flat Cables enables fast and realistic simulation of flat cables defined by their physical dimensions and material parameters.
• IPS Durability and Dynamics Software module for analyzing dynamic excitations that influence cable and hose behavior and durability. Enables reduction of physical prototypes by simulating small and large amplitude movements due to vibrations and steering angles.
• IPS IMMA Digital human model for fast and efficient evaluation of assembly ergonomics considering human diversity using a realistic biomechanical model.
• IPS Path Planner Automatic collision-free assembly or disassembly path planning software. Calculates optimum assembly paths for objects to be planned.
• IPS Pointcloud Tools Software that combines real-world scanned pointclouds with virtual world designs using algorithms for collision checking, distance measurement, and path planning in factory environments.
• IPS Robot Optimization Award-winning robotics technology for offline programming and work cell optimization. Allows automatic task planning, sequencing, and line balancing for robot stations. Proven results include 75% faster commissioning and 25% improved cycle time.
• IPS Sealing & Adhesives Software for accurate simulation of the sealing deposition process taking complex material rheology and surface flow into account. Enables off-line programming of sealing robots, simulating one meter of sealing material in less than one hour.
• IPS Virtual Paint Spray Software for accurate simulation of paint spray processes considering complex material rheology and surface flow. Enables full car simulation overnight on a standard computer. Optimizes painting process to be more environmentally friendly, energy and cost efficient, and improve product quality.
• IPS Virtual Reality Virtual reality tool that allows users to play simulations, manipulate flexible and rigid objects, use distance and collision measures, and assemble/disassemble objects directly in VR. Combines CAD geometries and scanned pointclouds.
• IPS fleX Hub Cloud-based online platform enabling smarter, faster, and higher-quality cable and hose design and validation workflows for the IPS software suite.
• IPS Training (fX Academy) Software training service offering regular training sessions and workshops on the use of IPS products. Includes basic seminars, advanced training, best practice sessions, and webinars for beginners and expert users.
• Engineering Services Specialist engineering services including troubleshooting, customized engineering projects, measurement of cables and hoses using MeSOMICS technology, and method development. Delivered by experienced specialist teams.

Quantifiable outcome

• 75% faster robot commissioning with IPS Robot Optimization
• +3 more outcomes

Named customers21 records

Segments5 records

Ideal customer profiles3 records

Technology focussed Yes

API detail

Has API

No

API docs

API detail

Core technology

AI maturity

App detail

Feature10 records

Partnerships

14 partnerships are on record, tiered strategic, regional, technology and core.

• BI-REX (Big Data Innovation & Research Excellence)strategicStrategic or Co-development Partner · 1 May 2025Italian Competence Center managing the PNRR funding call under which fleXstructures Italia participates in the AMATA project. BI-REX manages funding for technology transfer centers in industry segments.
• Hysim (China)regionalChannel Partner/ Reseller/ Distributor · 1 January 2025New distribution partnership for China established in 2025.
• Hoyetek Corporation (Taiwan)regionalChannel Partner/ Reseller/ Distributor · 1 January 2025Distribution partnership for Taiwan established in 2025.
• XsenstechnologyTechnology or Integration · 1 January 2025Motion capture technology provider integrated into AMATA project infrastructure. Xsens technology enables intuitive off-line robot programming methodology based on motion tracking.
• Sandalwood Engineering & ErgonomicscoreChannel Partner/ Reseller/ Distributor · 1 January 2020Distribution and technology partnership for North American market. Co-hosts IPS Innovation Summit North America with fleXstructures.
• Centricity Consulting Ltd.regionalChannel Partner/ Reseller/ Distributor · 1 January 2019Distribution partnership for United Kingdom market established in 2019.
• fleXstructures Italia S.r.l.regionalChannel Partner/ Reseller/ Distributor · 1 January 2018Italian subsidiary founded in 2018 to serve Italian market and support local customers.
• GLB (China)regionalChannel Partner/ Reseller/ Distributor · 1 January 2017Distribution partnership for China established in 2017. GLB provides IPS Virtual Paint user support including path planning for robot spray and sealing applications.
• Pan Information Technology (China)regionalChannel Partner/ Reseller/ Distributor · 1 January 2016Distribution partnership for China established in 2016.
• EMPIAS Inc. (Korea)regionalChannel Partner/ Reseller/ Distributor · 1 January 2014Distribution partnership for Korea established in 2014.
• SCSK Corporation (Japan)regionalChannel Partner/ Reseller/ Distributor · 1 January 2013Distribution partnership for Japan market established in 2013. SCSK also hosts IPS Cable Simulation User Conferences in Japan.
• Fraunhofer ITWMcoreTechnology or Integration · 1 May 2012Founding spin-off parent institution. Fraunhofer-Institut für Techno- und Wirtschaftsmathematik in Kaiserslautern specializes in applied mathematics for industry. Research at Fraunhofer led to development of IPS product portfolio. Mathematical methods create digital models of reality for simulation. Close ongoing cooperation for research projects.
• IPS ABcoreChannel Partner/ Reseller/ Distributor · 1 January 2012Spin-off of Fraunhofer-Chalmers Centre founded 2012 to handle marketing, sales and support of IPS software in Scandinavia. Located in Gothenburg, Sweden. IPS IBOFlow AB subsidiary handles surface treatment process simulation products.
• Fraunhofer-Chalmers Centre (FCC)coreTechnology or Integration · 1 January 2004Fraunhofer-Chalmers Research Centre for Industrial Mathematics in Gothenburg, Sweden developed IPS software algorithms. FCC develops simulation methods for prediction, control, optimization, quality assurance and risk assessment. FleXstructures and FCC work closely together in research projects.

Scale indicators4 records

Recent moves11 records

Expansion highlights6 records

Broad incumbents

• Ansys: Ansys is a broad multiphysics simulation incumbent whose structural and mechanical solvers can be applied to cable/hose durability analysis that overlaps with IPS Durability & Dynamics. Comparable as a CAE competitor addressing similar engineering-buying centers in automotive and heavy industry.
• Siemens Digital Industries Software (Capital / NX): Siemens' Capital (formerly Mentor Graphics) and NX offerings provide electrical wiring harness design and cable routing as part of a much broader PLM/CAD/CAE portfolio. They overlap with fleXstructures on cable/harness workflows but serve customers primarily through a much wider design suite rather than specialized real-time physics simulation of flexible components.
• PTC (Creo / Windchill): PTC's Creo Cabling extension and Windchill PLM platform offer cable/harness routing capabilities aimed at the same manufacturing-engineering audience fleXstructures serves. Comparable because PTC is increasingly pushing into model-based systems engineering and digital thread use cases that intersect with fleXstructures' virtual validation proposition.
• Rockwell Automation (FactoryTalk): Rockwell Automation's FactoryTalk and Arena simulation suites address manufacturing and robot-cell design from a controls-automation angle. Comparable to fleXstructures as an incumbent in industrial-automation software with overlapping customers in discrete manufacturing and heavy industry.
• Dassault Systèmes (CATIA / 3DEXPERIENCE): CATIA's Electrical & Fluidic Wire Harness Design modules compete with fleXstructures in the same automotive and aerospace customer base. As a broad PLM incumbent, Dassault can bundle harness design with surrounding design and simulation tools, putting standalone specialists like fleXstructures under bundle-pricing pressure.
• Altair: Altair offers simulation, optimization and digital-twin software across structural, motion and manufacturing engineering. Comparable to fleXstructures as a CAE competitor and as an adjacent provider in design optimization, with growing overlap in manufacturing-process simulation use cases.

Direct peers

• Zuken (E3.series): Zuken's E3.series is widely used for electrical wiring harness design in automotive and industrial machinery. It is directly comparable to fleXstructures' IPS suite in customer base (OEMs and harness suppliers) and in target workflow (harness design and validation), though Zuken competes more in the schematic/formboard layer.
• EPLAN: EPLAN provides engineering software for electrical design, including cable and wire harness layout. It is a direct functional peer to fleXstructures in the wiring-harness design domain, though it focuses more on schematic and ECAD workflows than on real-time physics simulation of cable behavior under motion.
• Visual Components: Visual Components focuses on 3D manufacturing simulation and robot offline programming — overlapping directly with fleXstructures' IPS Robot Optimization and work-cell design use cases. Both target manufacturing engineers seeking to validate and optimize robotic cells before deployment.

Emerging players

• RoboDK: RoboDK provides robot offline programming and simulation tools used by manufacturers and system integrators. It competes with IPS Robot Optimization in the offline programming and cycle-time optimization space, particularly for small and mid-sized industrial automation users.

Market position

Strengths5 records

Weaknesses5 records

Competitive moat5 records

Key risks5 records

Key highlights7 records

Customer concentration

• YouTubeyoutube.com/channel/UC7c_xoQ5H9zrQrokvnBFgFg
• LinkedInlinkedin.com/company/flexstructures

Compliance1 record

Revenue estimate

Valuation estimate

Number of profiles

Profiles1 record

Subsidiaries2 records

Funding overview

Funding rounds

Investors

Funding detail is available on the Subscription and Enterprise plan.Contact sales →

M&A

Investments

M&A and investment is available on the Subscription and Enterprise plan.Contact sales →

Frequently asked questions about fleXstructures