Based on the client’s requirements, a 3D model was created using Solidworks, and the structural capacity of the design analyzed with Solidworks composite simulation. Once the suitability of the laminate design was confirmed ‘temporary’ moulds were CNC machined which enabled us to realise and reveal all the complexities we could expect during production while maintaining an economical price, and three prototypes were constructed.

The first 2 prototypes were a success, meeting or surpassing the client’s requirement, but we felt on reflection we could do better on stiffness and weight. Using a combination of optimised topology software and an aggressive iso-grid reinforcing structure approach, computer simulations revealed we could improve part quality and weight. These simulation results were confirmed when the 3rd prototype was completed showing an increase in stiffness and in strength by a factor of 5 and 4.5 respectively. The new design also reduced the overall weight by 44%.

The ability to create the 3D model enabled us to analyze and improve the design over an already suitable design. Leveraging 20 years of experience allowed us to carry out the complicated new build methodology in a timely fashion and deliver outstanding results with no change to the pricing model initially outlined.