Problem
A legacy line of industrial lifting equipment was losing market share due to its heavy weight and high manufacturing costs. The challenge was to reduce the overall weight by 15% without compromising the 5-ton load capacity.
Approach
We started with a topological optimization approach. By simulating the extreme load cases using Ansys, we identified “dead zones” in the cast steel components where material wasn’t contributing to structural integrity.
Solution
I redesigned the primary load-bearing chassis using a combination of hollow extrusions and strategically placed ribbing. The design was entirely modeled in SolidWorks, utilizing advanced surfacing techniques for the cast components to ensure manufacturability.
Results
- Reduced overall weight by 18%, exceeding the target.
- Lowered manufacturing material costs by 12%.
- Maintained a safety factor of 3.0 across all critical load paths.
Visual Documentation Restricted
CAD models, assembly drawings, and fabrication schematics for this project are protected under a client Non-Disclosure Agreement. Abstracted workflow diagrams and anonymized system architecture may be shared upon request during a consultation.
Technologies, Tools & Frameworks
The specialized CAD platforms, automation scripts, and engineering tools employed.