Design Optimization

Our design starts with the file of your current product that you send to us. Even if you do not have the CAD drawing, sketch with enough information is usually adequate. We utilize several leading integrated software applications, depending on the complexity and requirements of your product. Special attention is made to the key features and product characteristics during the modeling. Product functionality guides us on how to perform motion studies and apply accelerations, sharp turns, and symmetries. Optimized product shape is then verified using the Finite Element Analysis (FEA). Any constraints are resolved and FEA is repeated until the design is fully optimized and functioning properly.

Examples of the design optimization process stages. The original product is optimized for weight reduction. All other parameters of the product are maintained without the compromise in performance.

The unnecessary material is removed, yielding 25% to 65% mass reduction depending on the optimized product. All final products are still made of the same materials as the originals and are CNC machined.

A final design is shared in 3D PDF so you can conceptualize the object in all six degrees of freedom.

Click the pictures below for an example of the Disc Brake and the Landing Gear main shaft model, courtesy of Tetra4D.