Virtual Engineering

Using the latest engineering software and hardware, Design Mill has the ability to create accurate, detailed virtual prototypes of new or existing systems and run a variety of sophisticated engineering simulations of the digital prototypes. Using the models as digital test cases, Design Mill can significantly reduce the need for costly physical prototypes and testing. Design Mill integrates large quantities of data by harnessing existing customer data and project deliverables from the entire team to create a more robust design, helping to decrease critical time spent in the design phase.

Our 3D modelers build a complete library containing every component and element of the entire system. With this library we have the ability to place components in many different configurations allowing the ability to test and analyze each configuration, finding the optimum balance and placement of components in a system.

Our systems engineering staff is composed of Mechanical, Electrical, Software and Human Factors Engineers, along with 3D Designers/Modelers, Gaming and Graphical User Interface (GUI) Programmers, Animation Specialists, Web Developers and Subject Matter Experts (SMEs). The benefits of using virtual engineering over traditional methods include:

• Improved conceptual design and design quality

• Lead to better technical decisions

• Easily incorporate late design changes

• Electrical and mechanical systems design

• Conduct Finite Element Analysis

• Conduct Human Factors Engineering

• Detect design problems earlier in the design cycle

• Provide design alternatives before project costs are committed

• Enable more effective internal design reviews

• Promote inter-departmental understanding earlier in the project cycle

• Allow non-technical personnel to gain a better understanding of design intent

• Visualize more ‘what-if’ scenarios during the design process

• Make modifications and improvements to existing systems

Reverse Engineering

Reverse engineering is the process of using a specialized laser scanner to scan existing gear to supply the engineer with a digital representation of your part or system. Scanning equipment captures 3D positions of individual points on the equipment, a skilled 3D technician will use the points as a reference to develop a completed model that contains the proper shape and model tree that can be modified later if necessary.

• Capture the item’s precise dimensional data

• Scan all sizes from the truck to the bolts

• Reconstruct a physical object as a 3D model

• Use when missing or insuffi  cient design documentation

• With the new model we can create animations, conduct FEA, pull dimensions, or even print it using our rapid prototyping 3D printer

Human Factors Engineering

Human Factors Engineering (HFE) is the analysis and evaluation of human performance within the required environment, with an emphasis on human capabilities and limitations. Our Human Factors Engineers evaluate a project from conception through deployment, achieving working solutions to your Human Factors needs. When teamed with our modeling and animation engineers, real world solutions can be achieved quickly and efficiently with minimal expense ensuring people can use the system safely and efficiently. Benefits include:

• HFE is a Department of Defense requirement

• Reduces human error

• Inputs can guide design decisions

• Identify problems of an existing system

• Adapt/design work stations to improve performance and safety

• Guide design decisions such as button layouts, display selections, and feature operations to generate an interface that is intuitive and easy to use

• Types of design analyses capabilities include:

• User-centered Requirements Analysis

• Mission Analysis

• Task & Function Analysis

• Critical Task Analysis

• Workload Analysis

• Baseline Analysis

Finite Element Analysis

Finite Element Analysis (FEA) consists of a numerical simulation of a design that is analyzed in order to validate the design. Using FEA, the design is simulated under actual conditions to verify that the proposed design will perform to specifications before building costly prototypes. Benefits include:

• Identifies a broad range of potential design problems

• Better insight into critical design parameters

• Evaluation of new design concepts and materials

• Identify critical design issues early in design cycle

• Solve difficult mechanical engineering analysis problems

• Substantially decreases time from concept to production

• Types of design analyses capabilities include:

• Thermal

• Structural Stress

• Shock and Vibration

• Fatigue

• Electromagnetic



Virtual/Rev. Engineering