Fractal Nexus
Automation Consulting & Engineering Software
Virtual Commissioning · Process Simulation · Custom Engineering Tools
Validate automation before it hits the shop floor — catch errors in the model, not the machine
Automation Consulting & Engineering Software
Virtual Commissioning · Process Simulation · Custom Engineering Tools
Validate automation before it hits the shop floor — catch errors in the model, not the machine
Fractal Nexus is an engineering consulting company based in Umhlanga, South Africa. We help manufacturing and automation teams validate, simulate, and build software for complex engineering projects — before they commit to costly physical changes.
Our background spans heavy engineering, robotic welding simulation, PLC programming, industrial-protocol integration, and bespoke engineering software — backed by 141 repositories across 5 GitHub organisations covering virtual commissioning, process simulation, industrial automation, and AI tooling.
Logic and sequencing faults surface during physical commissioning — at maximum cost. Virtual commissioning catches them in the digital model first.
Production constraints and cycle-time losses only become clear after layout decisions are locked. Process simulation surfaces them before you build.
BOM management, production planning, and quality data spread across spreadsheets with no audit trail. Purpose-built tools solve this without a large ERP spend.
Inspection reports, data extraction, and routine analysis consuming skilled time. AI tooling can automate the repeatable work and free capacity.
Validate PLC logic and robotics programs against a digital twin before physical deployment — catching errors before they become expensive rework.
Model production line configurations in Tecnomatix Process Simulate — identify bottlenecks and cycle-time losses before layout decisions are locked.
Custom tools for BOM management, production planning, and quality control — built for engineering workflows, not repurposed from general-purpose software.
Automate repetitive inspection, reporting, and data-extraction tasks using AI — free senior engineers for work that requires their expertise and judgement.
Across five GitHub organisations covering process simulation, virtual commissioning, industrial automation (Allen-Bradley PLCs), and custom engineering tooling. Internal demos available on request.
Practical background in robotic welding simulation, body-in-white assembly, and PLC commissioning across automotive production environments.
OPC UA, Modbus, Ethernet/IP, PROFINET — we connect simulation models and custom tools to real plant infrastructure, not just demo environments.
From writing ladder logic through building process simulation models to delivering custom ERP and planning tools — single point of accountability across the stack.
We focus on automation validation (virtual commissioning), production throughput analysis (process simulation), and custom engineering software for manufacturing teams. Most engagements involve helping teams catch problems before physical deployment.
We are based in Umhlanga, South Africa. Most of our work is deliverable remotely — simulation models, software, and code review don't require physical presence. On-site phases can be scoped where needed.
Most first engagements are bounded and low-risk: a diagnostic call, a focused audit of your current setup, a process model of one line, or a prototype tool. This gives you something concrete to evaluate before committing to a larger scope.
Process simulation: Siemens Tecnomatix Process Simulate. Virtual commissioning: digital twin environments with Allen-Bradley and Siemens PLC integration. Custom software: TypeScript, Python, C#, and industrial protocols including OPC UA, Modbus, Ethernet/IP, and PROFINET.
Tell us about your project — we'll respond within one business day.
A 20-minute call is enough to clarify whether virtual commissioning or process simulation is the right fit for your current challenge — no commitment required.
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