Product design engineering encompasses everything from basic product function to structural integrity, environments of use, reliability, performance, production methods, and cost to name a few. At Integrated Design Systems our design team accounts for parameters affecting design and prioritizes them at the beginning of a project to insure the final product performs as expected. These parameters typically include factors encountered during normal product use as well as extreme conditions. Unexpected occurrences can be experienced during misuse, environmental influences, shipping and handling as well as hundreds of other variables.

During design development structural analyses, mechanical analyses and many other studies are executed to verify the design integrity well before it is prototyped. Finite element analysis is frequently employed to study deflections and stresses within structures to optimize designs. When large mobile structures are designed, the center of gravity is computed using CAD to insure maximum stability. All parts are completely detailed based on the specific material and manufacturing process selected to produce that part. These include all plastics processes, sheet metal, machining, casting and dozens of other processes.

The final proposed design is finally tested by our client or a third party to evaluate its performance based on these predefined specifications. After a comprehensive analysis of the proposed design has been completed, modifications are made to finalize the design before production release.

Center of Gravity Calculations

These CAD images illustrate the affects of various load distributions on the center of gravity for this medical cart tipped at different angles. The red cone shaped geometry represents the locust of points from the center of gravity projected onto a floor.

Finite Element Analysis

The collapsible pallet shown in this image was required to comply with many load carrying specifications as well as a variety of environmental conditions. Finite element analysis of one wall was used to verify the design and load carrying capabilities.

The unusually shaped asymmetrical water storage tank was designed for a client in Australia to be marketed for domestic use. Finite element analysis was applied to the design to evaluate stresses and deflections caused by hydrostatic pressure. The final design successfully resisted the demanding asymmetrical load distributions.

Invention and Mechanism Development

Unique mechanical designs are often developed to satisfy clients with novel inventions such as automatic page turning device which was developed for handicapped individuals.

Preproduction Mechanical Designs and Prototype Evaluation

Many projects require subassemblies be structurally very rigid as well as mechanically reliable and smooth during operation as shown in this support arm for an x-ray system.

Design and Verification of Complex Plastic Assemblies

Complex geometries are often required to satisfy aesthetic as well as ergonomic and functional requirements as shown in these images for a handheld control panel. This assembly included a conformal specially designed rubber keypad as well as a display panel.

Preliminary Evaluation of Innovative Mechanical Assemblies

These mechanical assembles and structural evaluations represent a few of the many engineering evaluations were have completed for the diverse range of products we designed. In every case our designs have been tested and approved by our clients before they have been released for production.

Performance and Reliability Test Procedures

Preproduction parts are often tested under extreme conditions to evaluate safety and performance. These injection molded handles were subjected to sever loads before being approved for production. Minor design modifications were made to improve structural performance.