Improving the Reliability of Consumer Electronics Products through Realistic Simulation

By Neno
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Early product failures and product recalls are very costly. They result in loss of revenue, litigation, and brand devaluation among others. Hardware recalls are often costlier than software recalls as software patches can be easily downloaded and installed once flaws come to light.

Recalls and early product failures tend to happen over and over again. Why?

The answer is because engineering teams are constantly under the gun to improve product performance, reduce form factors, and reduce time to market, all while cutting costs. In order to mitigate risk, engineers need to develop a deeper understanding of the product behavior under real operating conditions and quickly evaluate design trade-offs based on overall system behavior.

Physical tests provide an excellent means to understand product behavior. However, physical testing is expensive and time-consuming. Simulation provides a cheaper and faster alternative to physical tests. It is critical to strike the right balance between physical tests and simulation during product development. In order to get the maximum bang for your buck, simulations should be deployed starting early in the design cycle when physical prototypes are not available and the design is not fully developed. The earlier you find flaws, the earlier you can fix them.

Graph: Relative cost of fixing errors in embedded systems

Since the cost of fixing flaws grows exponentially through the design cycle, identifying and fixing design flaws early in the design cycle is super critical. Not all simulation tools are created equal. You don’t need any answer. You need the right answer. For that, you need simulation tools that most closely depict reality. And you need answers fast. Hence you need product testing and validation tools with industry leading physics and solver technology. Those will make you obtain accurate solutions faster in order to help you improve product design, ensure product reliability and reduce time to market. Accurate depiction of material behavior and physics of failure are essential to obtaining realistic results. Such capabilities are critical in predicting the behavior of materials such as glass, adhesives, and polymers that have a high propensity for damage.

Consumer electronic products, especially mobile and portable devices such as smartphones, tablets and laptops, are subjected to a variety of operating conditions. The devices need to be designed to protect them from damage. Engineers need to ensure that “portable” doesn’t mean “breakable.” The challenge is to design a light-weight product that can withstand not just the loading cycles associated with regular usage, but also abusive loading scenarios that are encountered less frequently (According to surveys and insurance claim statistics, drop and water damage constitute the two most frequent causes of damage for mobile devices).

Simulation should be employed at the ideation, product development, and failure analysis stages in order to improve product quality and reduce time to market. Refer to the case study is this e-book to learn how a leading manufacturer of consumer electronics used simulation to improve the keystroke feel and enhance frame rigidity while reducing weight.

While drop during daily usage is a concern for mobile devices, transportation drops are the main concern for office equipment. Engineers are faced with the challenge of identifying the structural members that are most susceptible to damage and then improve their damage resistance while reducing the overall weight of the structure. Here’s how a leading manufacturer of office equipment designed a low cost printer that can withstand a series of transportation drop tests.

The examples above provide a snapshot of applications leveraging realistic simulation technology to successfully improve product durability while satisfying other constraints such as weight and cost. Learn more about how you can leverage this technology to improve your electronic product design. Read our e-Book, “Improving Product Performance and Reliability through Multiphysics Simulation.”

 

‘My Design’ webinar: how a typical furniture company turns ideas into reality?

By Lauriane
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Do you want to develop innovative and successful products?

Do you need to improve efficiencies and make the right decisions while reducing development time and costs? 

Dassault Systèmes has developed “My Design”, an integrated solution that expands your growth and helps increase your margin, making sure you develop a successful product that your consumers will love.

Click here to discover how a typical furniture company has rapidly developed a new office chair, with an integrated approach, from ideation to market launch. Imagine that all internal and external players can easily collaborate together.

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Marketing and Innovation

What if marketing and innovative departments could keep abreast of market needs by managing the free flow of ideas and providing multimedia dashboards?

With a few clicks, the Marketing Manager can easily consult design trends and blogs and monitor project status, all in real-time. Together with her colleagues, she can perform a detailed review of key trends, challenges and consumer expectations. With this visual information, managers can assign maturity levels bumping them up from proposal status, to concept through to validation.

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Creative Design

What if industrial designers and stylists used powerful and intuitive tools that allowed them to focus on innovation?

With CATIA, industrial designers can create freeform 3D sketches. It’s fast and easy to use allowing the user to explore more design scenarios in a short amount of time. He can transform ideas into a 3D reality while exploring detail design variations directly on 3D objects. Sketching combined with the intuitive act of painting demonstrates the power of realistic 3D modeling. Using subdivision-surface technology, the industrial designer can very quickly sculpt in 3D, while keeping surface curvature continuity under control.

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Decision Review

What if you could improve efficiencies and make the right decisions while reducing development time?

It’s time for important decisions to be made during a design-review session with the product manager, the CEO and the marketing manager. To ‘sell’ his ideas, the industrial designer is now using CATIA to present and promote projects with a high-end visualization and rendering solution.

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Concept Development

What if you could reduce development costs by enabling industrial designers and mechanical engineers to work in the same integrated environment?

Mechanical engineers can quickly design Sheet Metal parts by taking capitalized know-how and manufacturing constraints into account early in the design process. The engineer can intuitively manage the forming process directly in 3D and automatically generate flattened views from the 3D design part.

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Simulation and Validation

What if decision makers could harness accurate information to define the best consumer experience and make the right choices?

Integrating simulation in the design workflow improves quality and reduces the cost linked to physical testing. Now that the product is completely defined, all actors and decision makers can easily experience the final product in context and digital assets are ready to be re-used for marketing purposes.

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Conclusion

“My Design” is an integrated solution based on the 3DEXPERIENCE platform for Consumer Goods companies. It allows the free flow of ideas through social innovation and provides multimedia dashboards to keep abreast of market needs. With “My Design”, your company can develop innovative products faster and cheaper and deliver products consumers love.

Discover more

Watch ‘My Design’ Webinar: how to turn ideas into reality

Discover My Design Industry Solution Experience

Watch the video and Listen to Tomasz Bardzik, CTO of Nowy Styl Group

Find more about Dassault Systèmes’ in the Consumer Goods & Retail industry

How Zahner shows clients, “Your fantastic projects are buildable”

By Akio
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clicktotweetClick to Tweet: How @azahner shows clients
“Your Fantastic Projects are Buildable”

The following video features A. Zahner Company using the 3DEXPERIENCE platform to better communicate and collaborate with AEC project owners and team members:
zahner video 1

CEO William Zahner predicts future facades will increase in complexity, including more dynamic and kinetic aspects, and requiring an integrated platform. Such a solution will “open up opportunities for the design and fabrication community to do some really amazing things.”

The Zahner team found that developing precise 3D models gives reassures to clients that their risk is mitigated.

In addition, they are better able to communicate openly, transparently with clients, contractors, architects, subcontractors throughout the project.

Because of its complexity and the amount of coordination required, the Chrysalis Amphitheater was the flagship project where Zahner used the 3DEXPERIENCE platform.

The Chrysalis has no walls, so navigating around the model could have been a challenge. But with the cloud-based platform, they were able to point everyone to the same location for effective collaboration.

Watch the video to hear directly from Zahner’s CEO, COO, VDC Technical Specialist, Senior Project Engineer, and Advanced Manufacturing Engineer:

zahner video 2

clicktotweetClick to Tweet: How @azahner shows clients
“Your Fantastic Projects are Buildable”

Related Resources

The Chrysalis Amphitheater: Transforming AEC Through Collaboration

Facade Design for Fabrication Industry Process Experience



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