How do you optimize product design using software?

In aerospace engineering, great designs starts with function and size constraints. Engineers design meticulously, ensuring every component serves a purpose within defined spatial limits. Collaboration is key. Manufacturing, producibility, stress, thermal, aero, and tooling engineers provide critical feedback: Manufacturing Engineers: Evaluate manufacturability. Stress Engineers: Assess structural integrity. Thermal Engineers: Manage heat concerns. Aero Engineers: Optimize airflow interactions. Tooling Engineers: Streamline practicality. Through iterative refinement, the design evolves, a testament to human ingenuity and relentless precision. Aerospace engineering, where innovation meets the sky, is a pursuit with limitless possibilities.

In my experience it is really important to correctly define: the technological schematic and its requirement, different restriction ( size, operational, user, and etc.). One really good practice is to create technical sketch and preliminary design

Before design must be defined function and requirement. And then measurement and posibility performance. After proto typing debuging, simulation finaly fan out robust and reliability product

There is definitely something to be said about being somewhat cautious in the CAD software that you choose to use as what works for you right now may not be able to help you/the company grow. Lots of softwares can do basic 3d modeling but others specialise in metalwork/woodwork/plastics and no one really knows which program will be the most compatible in the future for other manufacturing standards. Do the research, ask other people in your industry and see if you can get a decent amount of help with setup in the beginning and support throughout the future. Don’t forget to shop around as there are multiple distributors of the same product don’t be afraid to stand your ground and ask for more support where you need it

My opinion is that the myraid of tools available can, in most cases. all serve the same functions. The best piece of software has nothing to do with CAD, CAE, CAM, UX/UI, programming or PCB layouts. Before all of that you need a good system architecture and diagrams are the ticket. I am personally biased to LucidChart but even power point or a big whiteboard will get the job done. Lay out all your system functions, key stake holders, inputs and outputs then design the system in illustrative form. Block diagrams, flow charts and systematic functional architecture. Review, iterate, improve then make a plan...what software you need will work itself out from there and so will your best design.

Before delving into complex numerical analyses, it is advisable to evaluate which components of the design can be substituted with standard hardware such as nuts, bolts, and springs, standard features like chamfers, fillets, and boreholes, and standard dimensions including stock thickness and diameters. Many design engineers are often taken aback by the significant improvements in reliability and cost reductions that can be achieved through the effective utilization of standardization. Furthermore, manufacturing facilities will greatly appreciate the ability to use standard hardware instead of having to design and produce specialized tooling.

During concept design it will help if we do benchmarking to understand how others have solved the problem. This will provide us with more options. Also it helps if this concept design is discussed with other Experts from manufacturing, final user etc before taking concept to the detailing phase

This is a great time to get the 'graybeards' involved. Go out to the machine shop and talk through your design with the people that will be building it. Get a call together with some of the installers. Talk them through your design and ask them to absolutely gut it like a fish. Find all the opportunities for improvement. Maybe you have 4 different size bolts, making assembly a pain. Maybe you have a weld in a position that just can't be done. Maybe you missed a sharp edge or pinch point that could hurt the user. Really get their experience and prior failures to help your design be the best it can be.

Maintaining a vigilant focus on the aspects previously mentioned, it's equally crucial to proactively anticipate future trends and integrate advanced features into our designs. This forward-thinking approach ensures that as we scrutinize for potential issues, errors, or gaps, our designs are not only current but also future-ready. By consistently aligning our design process with emerging trends and technological advancements, we position ourselves at the forefront of innovation, ensuring we remain leaders in our field. This strategic foresight in design evaluation and refinement is vital in staying ahead in an ever-evolving landscape.

One final word .... I'm huge on 'elegance through simplicity'. Constantly look for items to take away from your design and it still have the same function. Makes it easier, less expensive, and more robust. Make it super simple and beautiful all in one. You got this!!

Adding dfmea here will capture possible issues and rectification of same at design stage. Thinking about the manufacturing process at this stage will help to keep the required minimum wall thickness, radius , material etc will reduce iterations.

Material hardness is a critical factor that significantly affects machining processes in mechanical engineering. The hardness of a material determines how resistant it is to cutting, shaping, or abrasion during machining operations.Softer materials can be machined with a wider range of tools, while harder materials require specialized, wear-resistant tools. For instance, high-speed steel (HSS) tools are suitable for machining softer materials, while carbide or diamond-coated tools are better suited for hard materials.The hardness of the material affects the cutting speed. Generally, softer materials can be machined at higher cutting speeds,while harder materials require slower cutting speeds to avoid excessive tool wear and heat generation.

Software like Adobe Photoshop, Adobe Illustrator, or digital sketching tablets can be used for initial concept sketches.Tools like AutoCAD, SolidWorks, Rhino, or Fusion 360 are commonly used for creating detailed 3D models of physical products.Tools like ANSYS, COMSOL, or Autodesk Simulation can simulate product performance under various conditions. Virtual reality (VR) and augmented reality (AR) software, like Unity or Unreal Engine, can be used to create interactive product experiences. Adobe XD, Sketch, Figma, or InVision are used for designing digital interfaces and user experiences. Tools like Mastercam or Siemens NX CAM are used to generate CNC machining instructions.

I typically don't use photoshop or some expensive software for concept sketches. I just use pen and paper. But I do use solidworks for initial concept models and refine it from there. At times if the fundamental sketch is too difficult to alter because numerous features were built on it, I make a new rev 2 based on the new features with more properly configured dimensions.