The level of testing needed to bear out these design changes wouldn't have been possible without an integrated CAD and CAE platform, according to Wiersema. "By using the computer to do a lot of the door designs, we were able to filter out the ones that were bad, then take the right one and try it in reality to prove out the concept," he said.
It also enabled the group to explore more design concepts than they had traditionally done when subbing out simulation work to third parties, mostly because they were able to retain their intellectual capital. "When you're working in a single, integrated environment, there's so much knowledge of the tools and the materials behavior that you can actually make something more efficient and have insight into what exactly is happening," Wiersema said.
While integrated simulation isn't necessarily taking time out of Donkervoort's development timeline, it is significantly cutting back on the number of physical prototypes that need to be built, and it is encouraging the engineering team to go further in pushing designs, Wiersema said. "The more time you have, the more you want to develop, and there's no end to how far you can go with the detailed amount of information you can get out of these software analysis tools."
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Good point, Rob. As CAD and CAE become more of an integrated process as opposed to siloed tools done by different groups within engineering, there are bound to be design efficiencies. The real benefit, here, though was upping the number of prototype designs explored without upping the number of physical prototypes having to be built. Time saver and money saver.
Interesting article, Beth. That's a nice way to increase possibilities in design -- to do it with computers instead of physical prototypes. While the process may not have saved design time in this case, I would imagine it would inevitably save time as this practice becomes part of the standard design process.
Producing high-quality end-production metal parts with additive manufacturing for applications like aerospace and medical requires very tightly controlled processes and materials. New standards and guidelines for machines and processes, materials, and printed parts are underway from bodies such as ASTM International.
Engineers at the University of San Diego’s Jacobs School of Engineering have designed biobatteries on commercial tattoo paper, with an anode and cathode screen-printed on and modified to harvest energy from lactate in a person’s sweat.
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