How do FEA simulations save time and money in the design process?!

Implementing a new product is always a challenge – it requires investment, time, and thorough testing. Just a few decades ago, most errors were detected only during production or prototyping stages, which meant additional costs and delays. Today, companies have engineering tools at their disposal that allow them to check the product before its first prototype is created. One of the most important of these tools is FEA (Finite Element Analysis).

What does a project look like without simulations?

• The prototype must be produced "as a trial".

• Design flaws are only revealed during testing.

• Changes in the design mean additional costs and weeks of delays.

• It is more difficult to meet standards and certification requirements.

The result? The project becomes more expensive, longer, and riskier.

What does FEA provide in practice?

Numerical simulations allow for predicting the behavior of the structure even at the 3D model stage.

As a result, you can:

• Reduce the number of prototypes – instead of five, often just one is enough.

• Decrease material usage – the design is optimized, without over-dimensioning.

• Accelerate the certification process – the project complies with standards even before testing.

• Increase product safety – the design operates reliably under real conditions.

• Shorten the time to market – which provides a competitive advantage.

Examples from our projects:

Coffee Dripper

When designing the dripper, we developed several construction variants, analyzing flow and durability. Thanks to simulations, the client could choose the best solution even before the prototypes were made, significantly shortening the project timeline.

Children's Furniture

For a children’s furniture manufacturer, we conducted analyses in accordance with safety standards. Simulations confirmed the durability of the structure, and physical tests yielded results identical to predictions. The result? The furniture quickly passed certification and hit the market.

Industrial Tanks and Structures

In projects involving tanks and large-scale elements, it was crucial to check resistance to static and dynamic loads. Thanks to FEA, we optimized the design to ensure it met standards while also being lighter and cheaper to produce.

Automotive – Plastic Components

In the automotive industry, we conduct detailed simulations of the assembly and disassembly of plastic components, such as switches and fuel vapor absorbers. We also analyze misuse situations, such as excessive forces during assembly, improper compressions, or operational overloads. As a result, the design is resistant not only to correct operating conditions but also to user or service errors, minimizing the risk of complaints and increasing product durability.

In summary:

FEA is not just a tool for engineers – it is a real savings of time and money for any company introducing a new product. Simulations allow minimizing risks, accelerating implementation, and increasing competitiveness.

If you are planning a new product or want to optimize an existing one – contact us. We will help you check your project even before its first prototype is created.

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+48 781 790 989

inzynieria@designhere.pl

31 Wincentego Witosa St.

Kraków, 30-612

You can find us.