Strengthening the link through software

The next generation of simulation tools could help better synchronize manufacturing engineering and product design.

Today's digital manufacturing simulation tools are becoming more robust. At the same time, product lifecycle management (PLM) tools are better able to integrate them into the early stages of product development. Suppliers are offering tailored packages so that even midsize and smaller companies can benefit from digital manufacturing, once reserved for bigger companies. While technology is advancing, how best to use it may need to catch up.

“Traditional methods of product design that use 3-D CAD and digital mockup technology provide huge benefits. But they fall short in the discovery of potential design changes caused by manufacturing processes and maintenance issues,” said Don Brown, Chairman of Collaborative Product Development Associates (CPDA). He believes that, in many cases, these methods do not assess variation caused by either fabrication or assembly processes. Forging, stamping, and welding produce parts that vary within geometric tolerances. They cause changes to material properties, however slight. In assembly, interferences with machinery or ergonomic issues with laborers cause variation in fit and finish between parts. These issues go well beyond the performance-oriented packaging compatibility checks most automotive designs undergo.