Calculix: A Free Software Three-Dimensional Structural Finite Element Program
calculix.de
calculix.de
Of course we won't 1-shot a new CAD kernel but the human work will likely shift more towards identifying failure modes, specifying test cases and sometimes solving really hard details. Sometimes even working out details that have no precedent in literature or free code.
gmsh/Calculix is great. Sure it doesn't reach quite as far as Ansys, but you can solve real meaningful problems with it.
> we currently don't have a free CAD kernel
BRLCAD is OK and OCCT is pretty good. The hard part isn't the CAD kernel; it's the user interface and interconnects.