How Finite Element Analysis (FEA) can support the New Product & Medical Device Development Process

Many of the projects we deliver must be right first time, whilst incorporating challenging mechanisms and structures as well as a variety of materials. So, how do we overcome this challenge?

Doing hand calculations can be used for simple components but once you start combining multiple materials and complex mechanisms, they become limited in their usefulness. This is where Finite Element Analysis or, FEA, comes in. FEA allows you to build a computer simulation of your component, product or device that can be ‘virtually’ tested in the same manner you would a physical prototype. It does this by taking a CAD model and breaking it down into a finite number of elements which can then be analysed individually. A typical FEA model will have thousands of elements which make up a mesh that closely resembles the original components physical form.

Here at HD, we provide cost effective FEA services by using simulation software to optimise and verify our designs, and those of our clients too. We identify, then calculate load scenarios and conduct motion analysis of designs to ensure they conform to specified performance requirements. By using SW Simulation software, we will provide you with results for deflection, stress and strain. We also use SW Simulation for computational fluid dynamics and thermal analysis.

• Reduce component weight

• Improve rigidity / flexibility

• Reduce stress concentrations and thus improve fatigue performance

• Reduce costs by utilising thinner / less materials

• Allow lower grade, lower cost materials to be used

• Ensure products and components are safe

• Improve the sustainability of a project

Using FEA can be hugely beneficial to a project as it will typically reduce costs, save time and improve product performance. Further FEA advantages are lower environmental impact by using reduced material usage for optimised rigidity / flexibility / weight. Effective use of FEA throughout the process will ultimately ensure your design is fit for purpose.

Static FEA:

A linear static FEA is performed when the forces applied to a part or assembly do not change over time. A static FEA is the simplest form of FEA, and is performed exclusively on linear elastic materials, where small displacements are anticipated.

Dynamic FEA:

A dynamic analysis is performed when the forces applied to a part or assembly change over time. A dynamic analysis can be performed on either linear elastic or non-linear elastic materials. Common examples of a dynamic study include drop tests and vibration analysis.

Potential issues with FEA:

A frequent issue with FEA is that the original load cases and loading scenarios are incorrect so they don’t truly represent the actual load onto a component or system. We’ve found this risk can be reduced by taking the time to truly consider what is happening and using SW Simulation to identify peak loads and understand loading profiles.

One of the biggest issues we find with FEA being outsourced, is that the iterative nature of design optimisation can be broken or come too late. It’s typical for analysis to identify issues in a design, which subsequently require further investigation and design optimisation. Therefore, it is always an advantage to introduce FEA, as early as possible, into the design process. This means problems are identified more quickly and changes can be made to the basic design early on. Doing this well before extensive engineering is undertaken will significantly reduce time and therefore costs or delays.

HD offer industry leading FEA Services:

We are a design team who fully understands FEA results and what needs to be done with designs to achieve the outcomes our clients require.

Read about how we recently used FEA and Simulation to study and optimise the performance of an inhalation device.