AES CASE STUDY NEW PRODUCT DEVELOPMENT MEDICAL...

ADVANCED ENGINEERING SERVICES 12445 Augustine Drive, Suite 150, Santa Clara, Ca. 95054

ADVANCED ENGINEERING SERVICESENGINEERING DELIVERED!

2445 Augustine Drive, Suite 150 , Santa Clara, CA - 95054

Website - www.aesgs.com

Email - [email protected]

Cell - +1 408 386 3278

AES CASE STUDY_NEW PRODUCT

DEVELOPMENT_MEDICAL DEVICES

DATE: 07/01/2019

http://www.aesgs.commailto:[email protected]


NEW PRODUCT DEVELOPMENT: MEDICAL DEVICES


Product Developm

ent

Proto Build

Conceptualization

Design

Mold ability DFMEATolerance Stackup

Design Release

Validation

NEW PRODUCT DEVELOPMENT: SURGICAL DEVICE

User interface Devices intended to be used by doctors to conduct surgical operations

using iot technology. Surgeon’s hand movement and apparatus movement will be

captured and transferred digitally using mechanical and electronic devices. The same will

be replicated on the patient at different Geographies



Seam less integration with customer as Extended offshore team in New innovative product development

Conceptualization

Extensive brain storm session with team and subject matter experts to generate concept product. AES generated 5

concepts for components and assembly. Each concepts was validated thru feasibility study, ease of manufacturing

and cost

Design

3D Parametric models and assemblies were created for funneled concepts to enable space optimization. The

design process went on a minimum of three iterations which includes CAE Optimization, DFMEA, Tolerance

stack up and moldability checks


DFMEA

Design Failure Modes and Analysis conducted for the initial models, to ensure prevention of failure modes like

complex geometry, wall thickness, sharp edges, drafts etc.

Mold ability

Mold feasibility was conducted, recommended for better materials, Parting lines, Zero

drafts for bearing surfaces and Mould Temperature controls



MOLD ANALYSIS DETAILS FOR SURGICAL DEVICE

FOR REFERNCE ONLY-PART NO:PRT010908

EJECTION MARK

Parting line and tool draw

DRAFTDRAFT

Parting line




Parting line and tool draw

Negative Draft

Wall thickness Parting line




Parting line and tool drawEJECTION MARK

Parting line UNDERCUT ACTUATIONS Draft


Tolerance Stack up analysis

To identify permissible variations allowed in components and cumulative impact on assembly aTolerance

stack up analysis conducted for parts and assemblies, identified critical tolerance values and permissible

tolerances without affecting form fit and function

Validated with Root Square Sum method

Design Validation

Validated design about Form, Fit and Function and ease of

manufacturability

Drawing release

Detailed drawings with GD&T, datum's and CTQ created and

released into system. Resolved queries raised during soft tolling for

physical validation



Manufacturing engineering experts will be part of Product engineering team, as soon as feasaibile working

concept is developed, DFMEA, Mold ability and Tolerance stackup analysis will be conducted,

recommendation from manufacturing engineering team will be implemented in the design. On need basis

optimization done using CAE tools and techniques. Drawings released in the system will be ready for

manufacturing without any manufacturability concerns. This will mimise product iterations and reduce lead

time for NPD

Dedicated team for quick turnaround of projectProduct development cycle time was reduced by 20% by using our compressed Product development More than 50% of failure modes prevented using DFMEA, and moldability checkPercolated product accuracy requirements to components using tolerance stackup analysisSuggested better materials with self lubrication properties like Delrin

NPD strategy in AES :

Benefits to Customer



VALUE ADDITION IN PRODUCT ENGINEERING

PE-DFMEA -1

Before AES Suggestion Before AES Suggestion

Complex pockets of tiny size less than 1 mm, Design requirement which makes manufacturing difficult and

component may fail during production, in DFMEA we have identified Design Failure modes at early stages and

suggested for Design changes without affecting Form Fit and Functionality of component as well as assembly

Cost: Tooling cost reduced by 8% by modifying complex shapes (*data provided by customer )

Quality : Zero defects reported

Manufacturability: Suggested for soft tooling for proto build which will minimize production tool rework


PE-Tolerance Stack up RSS


• Conducted Best case and Worst case 11.50/11.38

• Cross verified with RSS 11.477/11.403

• Conducted Best case and

Worst case 11.15/11.05

• Cross verified with RSS

11.13/11.07

Conducted Tolerance stack up analysis for Bearing surfaces and mating components which has functional

importance. Calculated with best and worst case validated with Root Sum Square method. AES Suggested to

revisit Few dimensions which was not feasible to manufacture

Cost: Tooling cost reduced by 8% as per data provided by customer

Quality : Zero defects, customer not received any query from Mould maker for unachievable dimensions

Manufacturability: Wider tolerances based on Tolerance stack up analysis results

VALUE ADDITION IN PRODUCT ENGINEERING


VALUE ADDITION IN MANUFACTURING ENGINEERING

ME-Innovation in Molding-1


Conducted detailed manufacturability and mold

flow analysis. Implemented 0 draft for bearing

surfaces with redefining parting line and MTC

Savings Customer was provided with many

options for alternative materials . Tooling cost

reduced by 8% (*Data provided by customer)


Objective :

• The objective of this study is to figure out the best design variables which can minimize the friction that is induced due to the

various actions such as direct finger touch load and rotational moment induced by hand. The hand should be able to easily

rotate the system which is the roll action where as the End cap should not fall free when left or during application of force.

• Various input parameters such as the outer tapper angle, input taper angle, Spring washer pre tension load, Washer spring

constant, material, inner and outer surface area have been considered as key input parameters.

FEA Modeling :

FEA model is built for the said two parts.

Two parts are connected by a bolt along with a spring washer.

Task Executed:

• Four Load cases are run for every iteration as follows:

• Bolt pre-tension only ; Bolt pre-tension+ 1degree rotation

• Bolt pre-tension + Normal Force ; Bolt pre-tension + 1degree rotation + Normal Force

• Each iteration has 4 load cases, hence we have run 40 simulation results.

Conclusion & Reliability :

• The deign was optimized at 30N pretension load, with a 45degree surface contact angle and the best suited material for this

application is Delrin AF.

Cost Savings :

• The material was changed from Delrin 150 to Delrin AF due to which we were able to achieve 15% cost saving in the

component and a performance rise by 25% by choosing suitable variables.

VALIDATION AND OPTIMIZATION WITH FEA

0

0.01

0.02

0.03

0.04

30 45 55 60 65 70 75

Y Axis deformation (mm) wrt Outer Tapper Angle

Y Axis deformation(mm)

0

0.01

0.02

0.03

0.04

Y Axis deformation (mm)

Y Axisdeformation(mm)

0

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60

70

80

0 0.2 0.4 0.6 0.8 1 1.2

30° Degree Outer taper angle




65°Degree Outer taper angle



AES CASE STUDY NEW PRODUCT DEVELOPMENT MEDICAL...

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