We use analysis to predict performance and expose risk early.
Mathematical models, tolerance analysis, FEA, CFD and sensitivity studies.
We use mathematical modelling throughout our work. It’s often the fastest way to conduct initial prototyping and design iteration on mechanisms or mechanically functional subsystems.
These models are typically used to define optimal proportions and geometries for specific mechanism types, to anticipate loading and frictional effects, and to determine feasibility of a design based on its intended use case, before needing to build more expensive and time-consuming physical prototypes or complex simulations.
We use a range of tolerance analysis techniques at different stages of product development. In early stages we can apply basic tolerance schemes at an early stage, to inform our mathematical modelling and spot overlapping performance regions early.
As concepts develop, we can identify any critical tolerance chains and run isolated analyses to ensure functional prototypes reflect their intended function accurately and repeatably.
In detailed design, the focus shifts to more complex 2D & 3D tolerance analyses. Here we can create tolerance schemes at a device-wide level, and can build in process capability, metrology and other real-world data to robustly derisk tooling and manufacturing scale-up activities.
Our team routinely deploys FEA to assess design concepts, and avoid foreseeable mechanical failures that might otherwise be found in physical testing.
Our approach is geared towards optimising individual areas of a device, and proactively removing failure points through rapid iteration and test of digital models.
We use CFD to uncover hidden effects and behaviours within fluid systems.
Our approach is focused on answering specific design questions, such as pressure drop, flow distribution, leakage risk and sensitivity to geometry, so simulation results can directly inform design decisions.
We use sensitivity studies to understand which design variables have the greatest effect on product performance.
By varying key dimensions, forces, tolerances, materials or operating conditions, we can identify where the design is robust, where it is fragile, and where engineering effort will have the most impact.
We use root cause analysis to investigate technical problems that are not yet fully understood.
Our approach separates symptoms from causes, tests competing explanations, and builds a practical evidence base so that corrective actions are targeted at the real failure mechanism rather than the most obvious symptom.