CAD Solid Modeling

• A customer was in need of a molded, plastic lever arm which satisfied their strength requirements and the aesthetics of their marketing group. Annual volume for this part was 120,000 pieces per year. CAD solid modeling, proper material selection and finite element analysis resulted in a product which met all of the customer’s needs and was even retained through the next product design cycle.
• The desire was to reverse engineer, create solid CAD models, and detailed drawings for a series of complex components. The turn around was to be 24 hours, we successfully met and exceeded the customers expectations.

Cost Reduction

• A new revised product model required a significant cost reduction in two key customer mandated features. Those features provided the user with a kinesthetic position feedback and a mechanical drag or resistance to movement. A new design not only, provided the same features, but eliminated several parts and resulted in a patent.
• A new application called for a hand operated electro-mechanical interface to replace the old, all mechanical device. The cost target was to be no more than the old input device, but it must provide all of the same features in addition to the new demand for electrical signal output. Working with the customer all of the cost and feature targets were met also resulting in improved ergonomics and another patent.

Sensors

• The requirement was for a non-contact position sensor to fit in a unique application. Technologies were reviewed and Hall Effect was determined to be the most cost effective. Annual volumes would exceed 250,000 units. A sensor assembly was designed to meet the specific application with the result being a very cost effective, production assembly and two patents.

Sports Equipment

• A new machined aluminum riser for a competition bow called for a large envelope, with clean lines, while shifting the center of gravity as low as possible. Design was created and is scheduled for use by a member of the US Archery team.

Finite Element Analysis

• A customer wanted to minimize the deflection of a cross beam in a hydraulic press. Utilizing Finite Element Analysis (FEA) analysis we were able to tell the customer exactly how much deflection could be expected and suggestions for minimizing the deflection