Product Design and Engineering
Product Design & Engineering
At Simulex Solution, we specialize in delivering high-performance mechanical product designs that meet industry standards while ensuring manufacturability, durability, and cost-efficiency. With over 10 years of experience, we provide comprehensive design solutions for Industrial manufacturers, Food & Beverage industry, Packaging, Pharmaceutical, Oil & Gas and much more.
Our Process – End-to-End Mechanical Product Design
Requirement Gathering & Feasibility Study
The successful development of any mechanical product hinges on a thorough understanding of its intended purpose and inherent limitations. This process begins with meticulously identifying key functional, form-related, and environmental requirements, which then informs comprehensive technical feasibility studies.
These studies evaluate critical constraints, material selections, and applicable manufacturing methods. Concurrently, initial market research is essential to analyze competitive products and establish realistic cost factors. Finally, a well-defined project scope, encompassing a detailed budget and timeline, is crucial for guiding the product’s development from conception to completion.
Principle Design & Ideation
The design exploration phase is pivotal in arriving at an optimal solution, where multiple design possibilities are meticulously investigated. This involves generating numerous concepts through sketching and CAD mockups, followed by the creation of basic 3D CAD models for early visualization of structural integrity. Simultaneously, a careful evaluation of materials and component selection is undertaken, considering mechanical properties, weight, and cost implications.
To validate the proposed concepts, functional prototyping is employed, utilizing low-fidelity models to assess their practical application and feasibility. Furthermore, we leverage advanced simulation capabilities to predict performance and identify potential issues early in the design process, allowing for optimization and refinement. Complementing this, our detailed cost reporting provides clients with transparent insights into the financial implications of each design iteration, ensuring informed decision-making throughout the exploration phase.
Detailed 3D Modeling & CAD Design
Using advanced CAD tools, we create precise digital representations of the product.
- Parametric 3D Modeling – Ensuring flexibility for future modifications.
- Assembly Design – Developing multi-component interactions with moving parts.
- Motion Study & Kinematic Analysis – Evaluating mechanical motion efficiency.
- Tolerance Stack-up Analysis – Ensuring fit and function in real-world applications.
- Software expertise: SolidWorks, Creo, CATIA, AutoCAD, Inventor.
Engineering Analysis & Design Validation
To ensure durability and performance, we conduct in-depth simulations and testing.
- Finite Element Analysis (FEA) – Checking stress, deformation, and fatigue life.
- Computational Fluid Dynamics (CFD) – Simulating airflow, heat dissipation, and fluid behavior.
- Thermal & Vibration Analysis – Evaluating operational conditions and failure risks.
- Tolerance Stack-up Analysis – Ensuring fit and function in real-world applications.
- Design Optimization – Weight reduction, cost minimization, and performance enhancement.
- Software expertise: ANSYS, HyperMesh
Design for Manufacturing (DFM) & Assembly (DFA)
Ensuring that the design is optimized for cost-effective production and easy assembly.
- Material Selection – Evaluating plastics, metals, and composites for cost and durability.
- Manufacturing Process Selection – CNC machining, injection molding, sheet metal fabrication, casting, etc.
- Tooling & Fixture Design – Ensuring ease of manufacturing.
- GD&T (Geometric Dimensioning & Tolerancing) – Standardized precision and fit.
Prototype Development & Functional Testing
Before full-scale production, we create and test physical prototypes.
- 3D Printing & Rapid Prototyping – Creating early-stage models for quick validation.
- CNC Machining, Injection Molding, Sheet Metal Fabrication – Producing functional prototypes.
- Physical Testing – Conducting stress tests, impact tests, and operational simulations.
- Design Iteration & Refinement – Making improvements based on test data.
Manufacturing Support & Documentation
We provide comprehensive documentation to ensure seamless production.
- Production-Ready Drawings – Fully annotated 2D technical drawings and BOM (Bill of Materials).
- Assembly & Maintenance Manuals – Instructions for manufacturers and end-users.
- Vendor Coordination – Assisting in material procurement and supplier selection.
- Compliance & Certifications – Meeting ISO, ASME, ASTM, and other standards.
Post-Production Support
Even after the manufacturing phase, we extend our commitment to our clients by providing comprehensive, ongoing support for the entire product lifecycle. This includes meticulous design revisions and updates to implement enhancements and modifications, as well as thorough failure analysis and troubleshooting to efficiently identify and resolve any performance issues. We also manage obsolescence by proactively finding suitable alternatives for outdated components, and continuously explore opportunities for upgrades and value engineering to reduce costs while maintaining, or even enhancing, product performance.
Product Design & Engineering
Research
Concept Development
Packaging
Computer-Aided Design and Mechanical Design
Prototyping and Manufacturing
Aesthetics and
Styling
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