CATIA 3DEXPERIENCE, the Winning Partner for the DUT Racing Team

By Thierry

Dutch university students from TU Delft had only nine months to design and build a new version of their electric car that they hoped would once again lead them to victory in the 2014 edition of the Formula Student competition.

The team used design and simulation technology from Dassault Systèmes’  3DEXPERIENCE platform to design the DUT14, an electric car featuring numerous improvements over last year’s model.

Global Design Competition

Every year, some of the world’s brightest engineering students pool their talents to design what they hope will be the winning car in the annual Formula Student competition. It is an opportunity for 500 teams from all over the world to put their skills and imaginations to work during their free time, including evenings, weekends and holidays, for a good portion of the school year. In addition to the challenge, it is a tribute to the engineers who founded this competition over 30 years ago. “This international design competition was the idea of the Society of Automotive Engineers who thought that students graduating from engineering school did not have sufficient practical design experience, nor the right project management and team-working skills,” explained Tim de Morée, team leader, Formula Student team at TU Delft in the Netherlands. “So they designed the Formula Student competition to enable them to acquire all three.” Students must design, build, test and drive a formula-type racing car as well as create an associated business plan for potential investors. Contestants’ entries are judged based on a series of tests that include speed, design, safety, reliability, and cost.

Delft University of Technology is a repeat participant in this competition and winner of numerous Formula Student races in the past.

Tim de Morée is this year’s leader of TU Delft’s 86 students team. Once again the students attempted to outperform the other teams in three key races – Formula Student United Kingdom (FSUK), Formula Student Germany (FSG) and Formula Student Austria (FSA) – with their new and improved DUT14. “You may think that after designing 13 cars that we benefit from our past experiences and know-how,” de Morée said. “This is not entirely true since 80% of the team is new to this competition. The other 20% are the few alumni who participated in this year’s adventure providing us with their design and project management expertise.” As a result, de Morée’s team completely redesigned a vehicle from scratch. The four-wheel drive car has four equal motors that enable the car to accelerate even faster and to regenerate energy on all wheels while braking. “This constant reuse of energy allowed us to choose a much smaller and lighter battery package,” de Morée said.

Engineering Firm.com

The team is run like a small engineering company with students working in one of five departments: electronics, powertrain, vehicle dynamics, chassis and aerodynamics. “Team members are responsible for designing a part, for example the steering system or electrical wire harness. Only the most standard parts such as dampers or sensors were purchased from suppliers but we tried to do as much as we could by ourselves.”

The DUT14 was designed and tested using solutions from the 3DEXPERIENCE platform. Every “department” completed its objectives using the 3DEXPERIENCE solutions. For example, students used CATIA for their design work and the analysis and simulation solution SIMULIA to test their design concepts. “This was very beneficial due to our tight schedule and limited resources,” Marinus van des Meijs, chief engineer, said. “We had only nine months to complete the project, of which three were dedicated to design.”

Lighter, More Energy Efficient

One of the team’s objectives this year was to make the car lighter than last year. “With a lighter car we improve energy efficiency and performance when accelerating or braking,” van des Meijs explained. “The DUT14 weighed 155 kg, down from last year’s model, which weighed an already light 179 kg. We owe this success in part to the 3DEXPERIENCE platform and its integrated simulation solutions, which enabled us to test each design iteration with amazing speed and precision. “All five departments of our company shared the same designs so when one group made changes, the others saw the updated design in real-time,” van des Meijs said. “Moreover, design history was capitalized, which allowed us to go back to previous design versions if needed at the push of a button.

Most of all, potential design problems were detected early on and not when we were physically assembling the car, which would have hurt our timing.”

Also new this year were the tires for the DUT14. “We designed them ourselves this time and made them wider, with a smaller outer radius and lighter than last year,” van des Meijs said. “We believed it would improve performance. Here again, without the 3DEXPERIENCE platform we would not have been able to test if our design caused interferences when steering. We were able to look at 55 different design iterations with CATIA before finding the right configuration.

The electrical department used the CATIA Electrical solution to define the wire layout, splice positions and wire lengths. “CATIA helped us to position our wiring in the most efficient way while keeping total mass on par with last year’s model,” van des Meijs said. “It is also important to allow slack where the connectors are and not in the rest of the wire harness. CATIA helped us place them exactly where we wanted. One key value of CATIA Electrical is its ability to quickly produce a precise design for routing. We used the Flattening feature to create the wiring drawings at a scale of 1:1. This made it easier to visualize every detail, which was very helpful,” he said.

CATIA, a Winning Partner

The Society of Automotive Engineers would have been proud to see how the design competition they imagined provides participants with valuable engineering skills. The TU Delft team put these skills to good use winning the championship title at the Silverstone competition and receiving numerous awards at the Hockenheim race in Germany including the Audi ultra-award for best lightweight concept. “It was a heart-stopping few days of ups and downs but we did it,” de Morée exclaimed.

With CATIA we had confidence in our design and in our ability to come up with the best vehicle possible in a very short timeframe.”

Discover the full story in video on 3ds.com

CATIA, the Winning Partner for the DUT Racing team

Designing for the Medical Device Industry: Holistic Solutions

By Helene

This post originally appeared at Core77.

A Multi-Faceted Approach

Bringing a consumer product to market is a challenge in and of itself—taking an idea through concept development, business analysis, beta testing, product launch, and beyond. Add the FDA (Food & Drug Administration) to the mix, and it’s a whole ‘nother story. This is the challenge faced by medical device and product firms, which not only have to make a fully functioning, well-designed product but also have to put it through several rounds of rigorous testing by the FDA and other regulatory bodies.

The AliveCor heart monitor, designed by Karten Design.

“They’re parameters. They don’t stop you from doing anything, but they do make you do it in a way that you, as a user, would probably think is a good thing,” says Aidan Petrie, Co-Founder and Chief Innovation Officer of Ximedica,

an FDA-registered product development firm with an exclusive focus on medical products. On any given day, Ximedica is running 40 individual programs, overseeing the steps required to bring these products to market. “We don’t do anything that isn’t a FDA-regulated product,” says Petrie.

The timelines for these projects can run anywhere between two to six years. While time-to-market is not the primary driver, finding ways to close that gap can make a big difference in profitability. For companies like Ximedica and HS Design, closing that gap meant becoming International Organization for Standardization (ISO) 13485 certified. “There are so many regulatory and quality metrics that had to be put in place to satisfy those requirements that it made us a better and stronger company,” explains Tor Alden, Principal and CEO at HS Design (HSD). “It also put us to a level where we couldn’t just accept any client. We had to become more sophisticated as far as who our clients were and how we could say no or reach a point of compliancy.” By building those regulations into the design process, these companies are able to anticipate and plan for any potential timely obstacles from the get-go.

As the products become increasingly complex, so do the regulations around how they’re developed. Traceability of every decision is required for ISO and FDA compliance, ensuring that medical device firms have a standardized quality management process that they follow and document every step of the product’s development. Depending on the type of product, specialists are often brought in to advise different aspects of that process. “There are so many parts to the puzzle,” says Petrie. “We have a hundred and forty people, but we still need specialists all over the place. We have regulatory people on staff, but we also bring in other pieces that we need. While all the people we have in the building are experts in medical device development, when we need someone to develop some optics, we go outside for that. It’s very collaborative because nobody can do it all by themselves.”

As an FDA-registered developer and contract manufacturer, Ximedica takes products all the way through to clinical trials—a part of the process that comes with its own set of requirements all its own. Even a product as benign as a toothbrush, for example, calls for regulations under HIPPA (Health Insurance Privacy and Accountability Act) if it is being tested by people over the age of 65, under 18, or those living with certain medical conditions. Being able to connect these requisitions to product features in the beginning would allow a project manager to track deliverables and foresee any hurdles before the final design goes to Verification and Validation.

Concept design of a smartwatch

Companies like Dassault Systèmes hope to offer a holistic approach to these problems. Similar to how Ximedica has positioned themselves as the one-stop-shop for all of the components needed to bring a medical product to market, Dassault Systèmes’ Ideation & Concept Design for Medical Device creates a space for designers, marketers, specialists, and collaborators to bring an idea through all the phases of the design process. Powered by their 3DEXPERIENCE® platform, Ideation & Concept Design for Medical Device brings together automated market listening, 3D-drawing to 3D-design integration, traceability, and project management together in one program—in the cloud.

“It’s very challenging to get a medical product to market in less than two years,” explains Alden. “A lot of it has to do with how challenging it is from the FDA standpoint and getting it through the regulatory bodies, but a lot of it is making sure that everybody is working with the same sheet music. Most important is to capture the user needs upfront and translate them into quantifiable attributes.  Additionally we need to combine these user needs with the technical issues into a product requirement specification.  Managing all these aspects of a project, understanding all the players, and the regulatory milestones is vital to shortening the time to market.”

Check out Beyond the design of the Medical Device to dig deeper into this topic and access the “Ideation & Concept Design for Medical Device” information kit here, over on Dassault Systèmes’ site: Ideation & concept design for medical device.

Spotlight on Morphosis Architects’ Kerenza Harris: Teaching the Value of Parametrics from Concept to Fabrication

By Akio

Perot Museum of Nature and Science in Dallas

 

Morphosis ArchitectsFounded in 1972, Morphosis took its name from the Greek word meaning “to form or be in formation.” While the name alludes to the firm’s “dynamic and evolving practice,” today it might also apply to its innovative use of parametric design tools.

Since joining the firm in 2008, Kerenza Harris has been a key part of Morphosis’ development and integration of these new technologies into design work.

Today, she is helping Morphosis to develop automation systems and parametric tools that can be integrated from the earliest concept design stages through fabrication.

Raising Expectations

Owners, fabricators, and contractors are expecting highly specific information earlier than ever. “It is a bit of a challenge because it forces us to have more complex models earlier on,” Harris notes.

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Click to tweet: “Higher expectations from
owners require more complex models earlier”

In addition, some owners are beginning to expect highly sophisticated models as a baseline for design presentations. While Harris notes that modeling makes it easier than ever to show owners precisely how a project will work, it is creating new expectations about the designer-owner relationship.

Lost in Translation

Embedding such sophistication into models so early can also prove challenging later in the process—should the model need to translated into another format.

“Every time we need to communicate with someone, be it a contractor, fabricator or client, there has to be a phase of translation,” Harris explains.

When this translation occurs, there is always the risk that embedded information could be lost in the shuffle. By bringing contractors and consultants onto the same software and encouraging closer collaboration, such shuffles can be reduced.

The Intelligence of Parametric Design

Having detailed information from the earliest stages is the beauty of parametric design, Harris notes. Using one program from the first line creates an intelligent model with a history.

“We go from simple geometry; a line, a surface, a plane, a solid, to architecture; a room, a building, a door, a window. As we move forward, the window, for example, becomes embedded with additional information: it has a certain size and uniform specification,” Harris says. “As the idea becomes more cemented, it becomes architecture.”

Tweet: #ParametricDesign turns simple geometry into #architecture. @Dassault3DS @M0rphosis #AEC #BIM http://ctt.ec/4v3PB+

Click to tweet: “#ParametricDesign turns
simple geometry into #architecture.”

Along the way, models are imbued with an “intelligence” that can be linked to methods of fabrication, specific materials, assembly processes and so forth. This can prove especially valuable, Harris notes, when changes are necessary.

When information is imperfect or incomplete, it is possible to embed new information into the model without breaking down the entire system.

The Tools Make the Design

Tools such as CATIA have given Harris an edge in explaining the need for specificity to the students she taught in her former position at Texas Tech University, as well as in her lectures today.

Such software allows students to begin working with simple forms and shapes, and then develop those shapes into complex projects with specific materials and systems.

“We then have a model that has history, which allows us to add information without having to start over,” she points out. Having the right tools in the classroom also has helped Harris to emphasize the importance to students of moving from the “big idea” to the materiality of the future assembly.

“The idea has to be complete and you have to use these tools to develop it and make it a reality,” Harris says. She adds, “That’s how we’re able to have a lot of our projects built in the end: because we are very conscious of the materials and assemblies and reality of what these things are. If that can work with the big idea, that’s perfect for us.”

A Big Idea Realized

AIA seems to agree with Harris’ philosophy. Morphosis Architects won the AIA 2014 BIM Award in the categories of Stellar Architecture Using BIM and Delivery Process Innovation for its work on the Perot Museum of Nature and Science in Dallas.

Perot Museum of Nature and Science in Dallas. Photo credit: Roland HalbePerot Museum of Nature and Science in Dallas. Photo credit: Roland Halbe

Morphosis used parametrics in creating the museum’s façade, which is comprised of pre-cast concrete modules that are repeated and reorganized to form a highly complex geometrical pattern.

The software enabled the team to achieve an effect that appears random and unpredictable, but in actuality emerges from a rationalized, pre-fabricated system allowing for a more efficient construction and installation process.

The AIA jury noted that the project stood out “by how it leveraged BIM not just in design but in the shop drawing process, and in the fabrication and installation they achieved things in a time that would have been unimaginable otherwise. BIM assisted in fabrication, documentation, and implementation. The submitter had a willingness to share their digital files to better improve the project.”

In its submission, the project team revealed that the museum’s success depended on this integrated process. The accuracy of the early design allowed the team to share highly detailed 3D models with the owner, fabricators, and contractors who used them to develop shop drawings and even a framework for installation.

The result: a world-class museum delivered on budget and ahead of schedule.

3DEXPERIENCE Forum 2014

Kerenza Harris is a featured speaker along with Becher Neme at the upcoming 3DEXPERIENCE Forum in Las Vegas, November 11-12, 2014.

Learn more or register for this event.

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Related Resources

Morphosis Architects

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Façade Design for Fabrication Industry Solution Experience

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