In general, both simulated testing (via virtual analysis including FEA and CFD) and physical testing rely on a deep understanding of what can occur. Only once we understand what we are looking for can we address those issues specifically in the testing context. Free limited (express) versions of both FEA and CFD have become widely available embedded within most CAD softwares, which can be a danger. Built-in virtual simulation softwares allow designers to use a tool without paying the dues necessary to understand the technology. They may not even understand they are using FEA or CFD!

The challenge with any tool is it cuts both ways, and the sharper the tool, the more damage done when used incorrectly. If you don't know what you're looking for, any simulation is useless. If you don't know how to interpret the data developed, incorrect understandings will result. Even worse, if you don't know the underlying limitations of the software, inappropriate extrapolations will be made, particularly with express versions of software.

FEA and CFD are great tools if used with a clear purpose, by a qualified analyst and in a limited context. Physical testing expands the limits by adding reality checks that are always needed. And incorporating FEA into the design process can dramatically reduce the development time and costs. But it's a total package of understanding the function of the device and its operating environment, combined with correct application of virtual simulation and physical testing, which provides the confidence to go to production.

Here are some clear phases that are required in any product development, but note that product design and development is an iterative process.

These steps have to be understood at a top level for coherency, but it is usually different people and different skill sets that produce the deliverables required. Once in production, it is continuous quality monitoring, awareness of warranty issues and quick response to known issues which will avoid product recalls. Because as we have seen, product recalls can cripple even the most robust of manufacturers!

Motovated’s core business is helping small to medium manufacturers with most if not all of these phases. If you’d like to discuss any of these phases please don’t hesitate to call!