Design based on FEA reports

In a machine a recent company was developing, they had run into an issue where a seeming “ghost force” was breaking a part that moved a pin. They weren’t sure what the magnitude of this force was so I performed some finite element analysis to determine a range in which the magnitude of force might exist. After that, more analyses were run to determine a design that would strengthen the part while maintaining function and making it more suitable to be manufactured using injection molding.

This piece was then created after taking the design needs into account. The area around the long slot was thickened to ensure a greater strength and the entire part was designed to ensure a constant wall thickness. After seeing the design for this part, I was asked to redesign the sister part as well.

This piece focused on maintaining function and designing to be manufactured by injection molding. When the parts are connected via a hex bar, it looks like this: