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Solid Edge ST4 Event: Energist and synchronous technology
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Solid Edge ST4 Event: Energist and synchronous technology


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Dr. Andrew Thomas, CTO, Energist …

Dr. Andrew Thomas, CTO, Energist

Engineering and Medical Device companies that have undergone the process of acquiring other entities or products often find themselves with data that has been generated in CAD software other than Solid Edge. Even if the data is in the native package, the history tree can be comprised of a few hundred items and the designers knowledge. Manipulating this data for change is often a challenge many engineers fail to meet. Using synchronous technology can enable engineers to identify and change the models to meet the new requirements and be sent to manufacture in just a few hours.

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  • 1. Applying Synchronous Technology:
    Reusing and manipulating 3rd party CAD data
    Andrew Thomas, PhD., MIET
    Chief Technical Officer, Energist Group.
  • 2. Topics of Discussion
    • Who we are and where we are with Solid Edge
    • 3. Fast ECO’s
    • 4. Importing and reusing 3rd Party CAD data
    • 5. Solid Edge Simulation reducing prototypes
    • 6. Recommendations
  • Who we are
    • Energist Group includes Energist Ltd, Energist NA, Inc & MedArt.
    • 7. Small Business, with 50 personnel, $25m turnover.
    • 8. Facilities in Wales, UK, East & West Coast USA & Denmark.
    • 9. 11 years in business.
    • 10. Target audience in Dermatology, Plastic Surgery & Aesthetics.
    • 11. Bioengineering, product design & development, sales & marketing.
    • 12. Acquiring companies & technologies for growth.
  • What we do
    • The products we design vary from OEM products to skin coolers to permanent hair reduction to laser lipolysis devices.
    • 13. Our products treat a range of aesthetic and medical procedures.
    • 14. Our market advantage is that our products are good value, reliable & quick to market.
  • Our typical product
    • Our typical products are light based medical devices for use in the aesthetic industry.
    • 15. The number of parts vary from ~76 to ~3500
    • 16. Some critical components or assemblies are imported from vendors.
    • 17. Time to develop can be as quick a 3 months to as long as 18 months.
    • 18. Pre-production changes happen mostly on software and electronics which have little bearing on design.
    • 19. Post production changes are few due to regulatory restrictions and cost of retesting.
  • What are our design challenges
    • Chinese products. Low cost, generally untested, unapproved devices appearing on the US & European Markets.
    • 20. Different CAD packages in acquired companies.
    • 21. Picking up existing development with different CAD formats, mainly SolidWorks and AutoCad Inventor.
  • Why did we choose Solid Edge?
    • Our previous CAD system was a mixture of Mechanical Desktop, Inventor & Alibre Design.
    • 22. Deciding factors were productivity, support and cost.
    • 23. Ease of use (modeled a prototype for RP within 5 days – no training).
    • 24. Modeling aspects (assembly, part, sheet metal, piping, simulation).
    • 25. Editing power.
    • 26. Imported data handling.
    • 27. Drafting.
    • 28. We evaluated Solidworks at the time and, although it was a complete suite like Solid Edge, was not as user friendly.
    • 29. Something big was on the horizon….
  • What do we use Solid Edge for
    • Solid Edge for design, 95% Synchronous. Traditional used for Piping & Harness.
    • 30. Mixed assembly design
    • 31. Synchronous Sheet metal modeling
    • 32. Synchronous Part modeling
    • 33. All drawing production
    • 34. Some import and conversion from legacy data into 3D models
    • 35. Imported 3D supplier parts used for assemblies, part creation etc.
    • 36. Simulation used for design verification and model adjustment.
    • 37. Visuals for manufacturing assembly instructions.
    • 38. Model preparation for advanced rendering in KeyShotfor sales decisions on color & labeling etc.
  • Real World Example 1
    Using Synchronous for Fast Change
  • 39. Changing Designs with Synchronous Technology
    • Improved creation of parts and assemblies.
    • 40. Faster ECO’s. Changed the design (below) via Synchronous to be smaller than the previous design within 2 hours, relocating all internal parts and assemblies. Drawings and STEP files were distributed to manufacturing within the same day.
    • 41. New cooler design in now in production in the UK.
  • Real World Example 2
    Tackling CAD challenges
    Reusing Solidworks files
  • 42. Advantages of Synchronous Technology
    • Importing SolidWorks files (and finding geometry errors)
    • 43. Background - Existing files needed to be RP’d urgently but the original design format was in SW 2008. SE set for a Synchronous default Import.
  • Advantages of Synchronous Technology
    • Using Geometry Inspector, the imported file was checked for errors
    • 44. 2 Errors were found
  • Advantages of Synchronous Technology
    • On zooming in, the error can be cleanly seen as a missing surface and an overlapping edge.
  • Advantages of Synchronous Technology
    • A Tangent plane and a point was inserted for manipulation and targeting
  • Advantages of Synchronous Technology
    • Selecting the round and moved the steering wheel to the appropriate point for rotation about that point. Major Axis was aligned to the point.
  • Advantages of Synchronous Technology
    • Using the rotation on the Steering Wheel, the angle of the round was adjusted.
  • Advantages of Synchronous Technology
    • Using the rotation on the Steering Wheel, the geometry was easily repaired.
  • Advantages of Synchronous Technology
    • A second Geometry check was done, finding no faults in the part after the Synchronous repair was performed.
  • Advantages of Synchronous Technology
    • File was sent for SLS RP.
    • 45. Total time taken to change was 1 minute.
  • Using Simulation effectively
    Testing products before it’s too late
  • 46. Solid Edge Simulation
    • Real world simulation of temperature changes on materials (contraction).
    • 47. Handpiece for cooling the tissue during treatment.
    • 48. Input > Temperature drop from ambient to 3°C (37.4 F).
    • 49. Material was chosen and applied to the model.
    • 50. Simulation model was applied using “sliding along surface” on 3 faces.
    • 51. Calculation was run and displacement was calculated.
  • Business impacts from Solid Edge
    • Using imported data from other manufacturers parts allows assembly to be pin point accurate, reducing the need for prototypes.
    • 52. Manipulation of imported geometry from either traditional models or other CAD packages to change & reuse data.
    • 53. New products introduced within 3 months. Concept to production. This is purely due to SYNCHRONOUS design principles.
    • 54. Removes the need for sequential prototyping. In general only 1 prototype part is needed, if at all.
    • 55. Testing via simulation does remove the need for 1 further prototyping stage.
  • Ideas to Transition to Synchronous
    • Take advantage of the mixed environment.
    • 56. Take the tutorials on Synchronous and learn the steering wheel and live rules.
    • 57. There are many how tovideo’s on YouTube
    • 58. Use Synchronous to change existing parts for faster ECO’s
    • 59. New graduates that have trained on Solid Edge will be using Synchronous Technology. - “In a moving world, readaption is the price of longevity”
  • “The change from 2D to 3D was a huge leap in productivity, equally the change from history based to Synchronous is again a quantum leap towards Engineering Nirvana”
    Thank You!