Design Optimisation

Many structures, components, and parts are designed using experience, empirical data, or design rules which do not consider the detailed structural stress distribution, and can therefore result in overly conservative designs. Finite element analysis (FEA) enables detailed stress analysis of a structure, thereby facilitating the assessment of intricate structures and complex loading scenarios. Because of this FEA and stress analysis can be used as a basis for design optimisation, and can be coupled with existing experience and design rules to achieve the optimal design. The focus on optimisation using FEA and stress analysis at the design stage enables reductions in materials and weight, improved production efficiency, and improved product performance, while not compromising on safety or quality. Design optimisation is associated with short term material and fabrication cost savings, as well as with long term cost savings as a result of the improved product performance.

Topology optimisation techniques combined with FEA are used to find the most efficient structural shape for a given set of load conditions, thereby removing unnecessary material. SEAM uses topology optimisation as a basis for design optimisation, thereby finding the most efficient way to reduce component weight, without compromising on the structural performance.

We are experts in 3D Direct Metal Laser Sintering, also known as 3D Metal Printing, which allows the design of more complex components than traditional manufacturing without adding cost. We can combine our FEA optimisation capabilities with our experience in designing and producing parts which are compatible with this technology. This will ensure a successful build as well as successful performance of the part in service.

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Initial Design and FEA Stress Distribution

 

 

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Optimised Design and FEA Stress Distribution

Bracket Design Optimisation using FEA