Firm Cuts Seat Design Costs by 60% Using Topology-Optimization Software24 Apr, 2013 By: Beth Stetenfeld
Design Concepts calls on PareTOWorks, a new SolidWorks add-in, to confidently eliminate the metal hinge in a stadium seat.
Optimized Seat Design
The stadium seat project required a compromise, said Strahm, between cutting costs — by reducing the volume of plastic and fiberglass and eliminating the metal hinge — and ensuring sufficient structure to meet functional requirements defined by the ANSI/BIFMA X5.1 standards for chair performance.
These trade-offs were a perfect challenge for PareTOWorks, he said, because designers could set up the simulation so material was only reduced in predefined areas of the seat. Topology optimization allowed the engineers and design team to input predetermined measurements, industry standards, and materials parameters, as well as set predefined values for acceptable seat stress levels.
Front and back isometric views show the molded components of the redesigned seat.
In this type of design project, said Strahm, topology optimization software "allows the designer to quickly define and quantify structural areas important in the product-development process, when timing and budget considerations sometimes weigh heavily in the decision-making process."
For Strahm, being able to easily incorporate the software into his normal workflow was an added bonus. "It was nice to require only a brief overview of the new software, and then be able to use it right away. I didn't have to spend two to three weeks learning new software. It was fully integrated into our existing CAD package, and we could just start working with it."
Design Concepts began the project without PareTOWorks, then turned to the add-in software to test and complete the design. Strahm estimated that for a project like this, developing a working model the traditional way takes about a week. With PareTOWorks, in contrast, the first iteration was completed within minutes, requiring only minor adjustment to establish the first POP, he said.
Eliminating the Metal Hinge
The aluminum hinge in the original design satisfied a series of static loading and dynamic impact-testing requirements. Using PareTOWorks, engineers were able to integrate the functionality of the hinge into the plastic seat back and seat pan, eliminating 60% of the cost associated with the original design.
To satisfy the design constraints, engineers found a compromise between cutting costs through materials reduction and maintaining sufficient structure to satisfy the ANSI/BIFMA standards. PareTOWorks made this type of compromise achievable, said Strahm, "by allowing the user to set up the simulation such that material will only be taken away in predefined areas, and stress levels observed will remain below predefined values."
"We set the simulation to try to optimize geometry by reducing the materials volume," Strahm said. In effect, the engineers worked to make the plastic seat as light as possible, while still meeting manufacturing standards, performance expectations, aesthetic goals, and safety requirements.
PareTOWorks helps design engineers surpass the status quo, Strahm observed. They can move away from the old strategy of benchmarking known designs, so there's more potential to develop truly unique products.
Using traditional benchmarking and hand-calculation methods, Strahm said, "you're afraid to be creative; you're afraid to go off the beaten path because of very serious consequences." Having the parameters entered at the start, and then designing free of those concerns might inspire a more original design, he said.
"We work closely with industrial designers. There's a lot of communication back and forth — engineering vs. aesthetics. This tool defines for me the important engineering structural elements, and I can provide more definition to the industrial engineers about the ultimate end product."