Product Development Archives

How We Solved Halo Issues in Ophthalmic Imaging Design

Product Development

When designing a compact ophthalmic imaging device to enhance usability for doctors, achieving precise and reliable imaging is crucial. These devices rely on a combination of optical components, reflective surfaces, and light paths, so carefully managing factors like reflection and refraction is essential.

During the development of this compact device, we encountered a significant issue: a halo light effect forming around the light point in the image. This unwanted light artefact was causing visual interference, affecting measurement accuracy, and compromising diagnosis clarity.

Root Cause Analysis

Upon investigation, we determined that an unintended reflection from a metal surface within the optical path caused the halo light effect. While metal is ideal for structural durability, its reflective properties create secondary beams of light, resulting in the halo effect.

Key Features of the Device:

Adjustable slit light length and width for flexibility.
Brightness control for optimized illumination.
A compact design for ease of use in clinical settings.

These features make the device versatile but also introduce complexity in ensuring an accurate and uninterrupted optical path.

The Solution

To address the issue, our engineering team performed a detailed analysis of the optical path to identify reflective surfaces contributing to the halo light effect. Instead of a costly redesign of the metal structure, we applied a simple yet effective solution:

The reflective surface causing the disturbance was coated with non-reflective black paint.
This eliminated the unwanted reflection without compromising the structural integrity or requiring changes to the overall design.

The main optical path, which is made of stainless steel for durability and precision, remained intact. By isolating and addressing the problematic surface, we successfully removed the halo effect, ensuring a clear and accurate image for the device.

Lessons Learned

This experience highlights the importance of thorough diagnostics during the design phase. While advanced optical engineering is critical, simple solutions, like modifying surface finishes, can often address complex problems effectively. By incorporating this adjustment, we delivered a functional prototype without any delays or additional manufacturing costs.

AUTHOR

Dhanasekar is a skilled design engineer specializing in CAD and 2D drafting. With expertise in technical drawing and project management, he excels at transforming concepts into detailed designs. Dhanasekar is dedicated to delivering high-quality solutions that meet project requirements and timelines, driving innovation in every endeavor.

Stop Evaluating Technology Partners on Cost Alone: 5 Takeaways for Hardware Startups

Product Development

Building a successful hardware product requires the right technology partnerships. In a recent episode of the Creations Engineered Podcast by Srushty, Teja Gadamsetty hosted Simon Fabien, founder of Wetflix, to discuss the challenges and opportunities for startups, especially when visiting India to identify tech partners. Here are five actionable takeaways from their insightful conversation.

1. Define Your Partnership Needs Before the Visit

Simon emphasized the importance of clarity in your requirements before engaging with potential partners.

“Startups often think they need a one-size-fits-all solution, but clarity on whether you need prototyping, full-scale manufacturing, or just technical expertise can save you weeks,” Simon explained.

Take time to create a checklist of what your startup needs. Are you looking for a prototyping partner? Do you need expertise in a niche field like IoT or medical devices? Answering these questions before your visit will help streamline your search.

2. Leverage India’s Unique Strengths in Engineering

India’s technology ecosystem is diverse, offering expertise in areas like IoT, AI, and hardware prototyping. Simon shared his experience of working with Indian tech teams:

“The level of engineering talent you’ll find in India is unparalleled for the cost. But beyond cost, what stood out for me was their problem-solving mindset,” he said.

When visiting India, research tech hubs like Bengaluru, Hyderabad, and Pune, cities known for their engineering capabilities, to find the right fit for your project.

3. Focus on Cultural Fit and Communication

A successful partnership is more than just technical skills; it’s about aligning on values and communication. Teja pointed out that cultural understanding goes a long way:

“Tech partnerships are relationships. If you’re able to align on goals and communicate effectively, your collaboration becomes exponentially smoother,” he said.

Schedule face-to-face meetings or virtual calls to evaluate not just technical expertise but also how well the team aligns with your startup’s vision and work culture.

4. Visit Partner Facilities During Your Trip

One of the biggest advantages of visiting India in person is the ability to tour facilities and meet teams. Simon emphasized this point:

“Walking through the factory floor and seeing their processes firsthand gave me confidence in their capabilities. You can’t get that from an email or a Zoom call,” he said.

A visit allows you to verify quality standards, understand workflows, and ask questions about timelines and challenges they’ve solved for previous clients.

5. Build Long-Term Relationships

Finally, think beyond the immediate project and focus on creating lasting partnerships.

“The best partnerships I’ve had are the ones where we built trust over time,” Simon noted. “Having a partner who evolves with your needs is invaluable.”

Invest time in maintaining relationships even after the initial project is completed. Regular updates, collaborative problem-solving, and mutual respect can lead to a partnership that scales with your startup.

Are you evaluating a partner on cost alone? Think twice!

When Simon first started Wetflix, he quickly realized that building a smart water management device required expertise that went beyond his in-house capabilities.

“We needed someone who could help with both the hardware design and the IoT integration. It wasn’t something we could tackle alone, especially as a small team with limited resources,” Simon shared.

However, his initial attempt at finding a partner wasn’t successful. “We rushed into a partnership based on cost alone, without fully vetting their technical skills or understanding their working process. That mistake cost us six months and significant budget overruns,” he explained.

Simon learned the hard way that choosing the wrong partner can lead to delays, misaligned expectations, and even compromised product quality. “It’s critical to invest time in due diligence. Visit their facilities, ask for references, and make sure they’re the right fit for your specific needs,” he advised.

India offers an incredible opportunity for startups to find innovative, cost-effective technology partners. By following these tips, defining your needs, leveraging engineering talent, ensuring cultural fit, visiting facilities, and building long-term relationships, you can maximize the value of your partnerships.

Are you looking to create your hardware product? Here’s our Hardware Product Development Playbook that helps you get started!

Ergonomics on Trial: Frugal Prototyping to Understand Ergonomics

Product Development

Hello folks, hope you are having a good times and glad to see you again here.😄

This time we want to discuss how we solved a major ergonomic issue in a wearable product using a very simple method of prototyping. Though we have used simple materials and crazy fastening methods we have good insights and results from our test😮. So let’s dive into another amazing story of design 🧐……

Why is ergonomics important ?

Before getting into the content let us have a quick brief on ergonomics and its importance in product design. To keep it simple it can be described as – The goal of ergonomics in design of products is that they are easy to use and fit people comfortably and safely. In product design, it is crucial because it increases user comfort, eases strain, and boosts productivity.

Now let’s start our BTS on how we solved a major ergonomic issue in one of our product development –

The core challenge

The goal is to design a wearable harness that would be used as a sports training aid. So, the target user group is vast, involving teens to adults and male-female people.

After thorough research on the gameplay and human anatomy and rigorous brainstorming we chose to go with the best preferable option of designing a wearable harness over the chest area that will control the game play efficiently, but the groundbreaking challenge was to design a “UNISEX” sport harness with enhanced usability.

Approach towards solution

In the way of finding an apt solution for the harness, we initially did a good amount of research to understand human anatomy and anthropometrics. As the gameplay was so dynamic in human action, we needed to design a very flexible wearable design. Apart from the mechanics involved in the product the design of the apparel needed more attention towards size, shape, material and its properties.

We needed a chest pad that pivoted the game play mechanics onto it. We need to design this with utmost care that not only controls the movement efficiently but also has to stop any shock that might travel towards the chest.

Getting the hands dirty

We put a lot of thoughts through the ideation process by sketching and brainstorming. With some concepts in hand, we moved forward to test them on ergonomics in real-time. But before going to purchase the exact material and proper stitching we need to address over few points

Measurements – to fit all kinds of people.
Flexibility – required flexibility of apparel to allow essential action.
Material – to provide comfort as well as flexibility.
Shape – that meets all kinds of users which is unisex.

So we started off with basic materials such as foam boards, market ready nylon straps, buckle, adhesives, staplers and pins. Yes, this is all we needed to get an answer for all the basic parameters mentioned above before getting into a full fledged prototype.

With some basic skills our team put their hands to do this prototype to check on the ergonomics.

With this we have got most of the required insights to check the product ergonomics including the shape factor of the chest pad, measurements and few problems to address in the next phase too.

Conclusion

A quick prototype can help us to solve potential problems in product design. In specific if we get to use our creativity we can get to see more hidden problems early in the product development stage. This would help us to keep up the work ahead and with minimal investments we would be able to achieve better designs.

Hope you had a good read through this content. This is all for this week folks, let us catch up in the next week with more interesting topics on Industrial design.😎🙌

If you have any needs, reach out to us, we are here to bring your ideas to life!🤝

AUTHOR

As an innovative Sr. Industrial Design Engineer, he specializes in creating functional and aesthetically pleasing products. He blends creativity and technical expertise to develop designs that enhance user experience and meet market needs. He has contributed to a diverse range of projects, from consumer electronics to furniture design. He is known for his attention to detail and commitment to sustainable design practices, always striving to push the boundaries of what is possible.

AI-Audio-Processing-noise-cancellation-srushty

Why Breaking the Noise Barrier in AI Audio Processing Is So Complex

Product Development

AI-powered audio devices are transforming the engineering landscape. From analyzing speech patterns, tone, and cadence to detecting anomalies or enhancing user experiences, these devices are pushing the boundaries of what audio processing technology can achieve.

Imagine detecting depression or anxiety from voice recordings by analyzing speech patterns, tone, and cadence. Using AI-powered headsets to issue commands or dictate notes in noisy environments like construction sites or factories.

These are just a couple of examples showing how AI is transforming human interactions by deciphering audio. The possibilities are endless!

But there’s one constant challenge that remains - noise cancellation

You might think, “Isn’t that a problem of the past? Don’t we already have advanced AI tools that cancel out noise at the press of a button?” Sure, for simple use cases, they work great. But when it comes to complex, real-world scenarios, like handling emergency calls in chaotic settings or transcribing conversations in loud public spaces, noise becomes a whole new beast.

Noise has always been the audio processing engineer’s worst nightmare. Now, AI is the one trying to make sense of it all, and the challenge has only grown. While today’s tools can deliver impressive results for straightforward tasks, complex use cases demand far more. They require thoughtful, sophisticated engineering solutions to overcome the limitations of existing technology. And that’s where innovation truly comes into play.

The challenge with noise cancellation

The use case in the project that we worked on was, AI should transcribe casual conversations between individuals. It has to determine the individuals by identifying different speakers in the environment. This information is further processed with AI.

One of the biggest challenges in recording conversations of desired individuals is that most of the microphones available in the market are omnidirectional. These mics pick up sound from all directions at the same levels of intensity. This makes it difficult for AI to decipher casual conversations since there might be overlapping conversations coming from areas which are not of our interest. Hence, we opt for a unidirectional mic which is a combination of more than one mic.

For instance, we could achieve a cardioid pattern using an Omni & dipole (captures audio in the front and rear while mitigating the sounds coming from other angles) mic. But even these unidirectional mics are not perfect if the desired and undesired sound comes in the same directions – And they can still pick up background noise and other sounds, but at a comparatively reduced intensity.

But aren't they unidirectional?

Newsflash: Unidirectional mics don’t work in just one direction- they are designed to be most sensitive to sound from the front, while reducing the intensity of sound from other directions. So, don’t assume that a unidirectional mic will completely reject/eliminate background noise.

So, how do we overcome these challenges?

We use a combination of techniques to achieve the desired output. First, we use multiple mics to minimize the ambient noise. This helps us capture the audio from the front while reducing the intensity of sound from other directions.

But There's More

Even with beamforming, managing reverberation and echo remains a challenge when placing microphones within enclosures. This is where digital signal processing (DSP) comes into play. We use DSP techniques, such as applying low-pass or high-pass filters, to remove unwanted frequencies and reduce the impact of ambient noise. Additionally, we must carefully balance the normalization of loudness and amplification to ensure that the desired audio is preserved while minimizing unwanted sounds, achieving the optimal recording quality.

There are several trials and errors involved in understanding the right enclosure material, size, and air gap within the cavity to minimize reverberation and echo while maintaining audio quality. We rely on cost-effective frugal prototypes to refine and find the optimal solution.

Noise cancellation is a complex challenge that demands a combination of techniques and meticulous attention to detail. By using multiple microphones to create a unidirectional pattern through beamforming, applying passive filtering, and leveraging digital signal processing to further refine the audio, we can isolate the desired audio and minimize unwanted noise, achieving the optimal output.

AUTHOR

As an accomplished Electrical Hardware Engineer, she focuses on the design and development of cutting-edge electronic systems. With a strong background in circuit design and embedded systems, Geetha plays a pivotal role in driving innovation and ensuring the reliability of our products. She has successfully led multiple projects that have enhanced product performance and efficiency. Her analytical mindset and attention to detail enable her to tackle complex engineering challenges effectively.

Design-failure-mode-and-effect-analysis-on-product-design-and-development

What is DFMEA? Comprehensive Guide for Risk Management for Product Design

Product Development

Are you new to Design Failure Mode and Effects Analysis (DFMEA)?

This comprehensive guide will walk you through the process step by step, highlighting key strategies and common mistakes to avoid.

Here you can know, why DFMEA has become a cornerstone in modern corporate practices, enabling engineers to proactively address design risks and save businesses from costly missteps in materials, processes, and manufacturing decisions.

DFMEA is one of the key types of Failure Mode and Effects Analysis (FMEA). Here’s an overview of the main types:

Types of FMEA Analysis

Design FMEA (DFMEA):Targets potential failures in product design to ensure products meet design and functional specifications.

Process FMEA (PFMEA): Examines manufacturing and assembly processes to identify and correct potential process-related failures.

System FMEA (SFMEA): Analyze the entire system’s potential vulnerabilities to ensure all components work harmoniously.

Service FMEA: Focuses on potential failures in service processes and their impact on customer satisfaction.

Software FMEA: Identifies potential failures in software systems and their effects on functionality.

Manufacturing FMEA: Like PFMEA but specifically targets manufacturing processes.

What is DFMEA?

Design Failure Mode and Effects Analysis (DFMEA) is a structured approach that aims to identify, analyze, and mitigate risks related to a product’s design before it goes into production. DFMEA focuses on failure modes- the ways a design might fail – and evaluates their effects on the overall system. The primary objective is to recognize and reduce risks early in the design phase to save time and resources that could be needed for late-stage fixes.

What is the purpose of DFMEA?

Risk Prevention: Identify and eliminate potential design issues before they affect product quality or lead to customer dissatisfaction.

Product Reliability and Safety: Enhance the product’s ability to perform reliably and safely throughout its lifecycle.

Cost Savings: Reduce costs associated with recalls, warranty claims, and field failures by addressing problems early.

Compliance: Meet regulatory and industry standards for risk management.

Improved Collaboration: Foster teamwork across design, engineering, and quality assurance, ensuring comprehensive input in the design process.

The purpose is to gauge the potential impact of each failure on the product’s reliability and safety.

Types of Representation DFMEA

Boundary Diagram: Also known as a block diagram, it defines the scope of the DFMEA by identifying the system boundaries and interfaces.

P- Diagram (Parameter Diagram): Shows the relationship between different parameters and how they affect the system.

DFMEA Worksheet: A structured form used to document the analysis, including potential failure modes, effects, causes, and actions.

Design Verification Plan & Report (DVP&R): Outlines the verification and validation activities to ensure the design meets requirements.

DFMEA example table

DFMEA (Design Failure Mode and Effects Analysis) table is a structured tool used to identify and evaluate potential failure modes in a product design, their effects, causes, and the actions needed to mitigate them. Here’s a typical layout of a DFMEA table

Assign Severity, Occurrence, and Detection Ratings

Severity (S):

How serious is the impact of the failure on the product or user? This is typically rated on a scale of 1 to 10, with 10 indicating a severe consequence (e.g., a failure leading to injury or major product malfunction).

Occurrence (O):

The likelihood of the failure mode happening. Higher scores indicate a greater probability of occurrence, typically based on historical data or expert judgment.

Detection (D):

The ability to detect this failure before it impacts the customer. Lower scores mean failure is easier to detect, while higher scores indicate it is challenging to catch before it occurs.

How to calculate RPN in FMEA?

The Risk Priority Number (RPN) is a scoring system that helps prioritize each failure mode based on its Severity, Occurrence, and Detection ratings. The RPN is calculated by multiplying these three scores:

RPN = S × O × D

High RPNs (closer to 1000) indicate critical issues needing immediate attention.
Moderate RPNs suggest areas that may require design adjustments.
Low RPNs may not require immediate action but should still be monitored.

Developing and Implementing Corrective Actions in DFMEA

Based on the RPN scores, the team develops corrective actions to reduce the identified risks. This can involve design changes, material substitutions, or process improvements.

Common corrective actions might include:

Strengthening materials
Adding sensors to detect potential failures
Redesigning parts to reduce wear

These corrective measures are documented, implemented, and evaluated for effectiveness.

Re-evaluating and Updating DFMEA

Once corrective actions are in place, the DFMEA team should re-assess the RPN to determine if the risk has been adequately mitigated. DFMEA is a living document that requires periodic updates, especially if new failure modes are identified or changes are made to the product design. Regularly revisiting DFMEA ensures ongoing risk management throughout the product lifecycle.

Summary

In identifying probable failure modes and evaluating their consequences, the DFMEA process is essential to improving a design’s robustness. The team may successfully reduce risks and guarantee that the design satisfies the highest quality standards by working together and doing methodical analysis. The DFMEA promotes reliability and ongoing improvement in the finished product by putting corrective actions into place and keeping an eye on them. This proactive strategy improves consumer happiness and confidence in the product’s performance in addition to protecting against possible faults. In the end, DFMEA is a crucial instrument in the pursuit of design and manufacturing excellence.

Hot Runner Injection Molding Explained: Advantages and Use Cases

Product Development

Injection molding is a fundamental process in the manufacturing industry, and it is used to produce plastic parts with high precision and efficiency. Among the different injection molding techniques, the hot runner system stands out for its unique advantages over traditional cold runner systems. In this blog, we’ll dive into the hot runner injection molding process, compare it with cold runner systems, and explore what makes it special compared to other methods.

What Is Hot Runner Injection Molding?

Hot runner injection molding involves a system where molten plastic is kept hot and fluid as it moves through a network of heated channels (called runners) directly into the mold cavities. In this process, the plastic does not solidify in the runner but is continuously kept in a molten state, allowing it to flow smoothly into the mold.

How It Differs from Cold Runner Injection Molding

The primary difference between hot runner and cold runner injection molding lies in how the plastic material is delivered to the mold:

1. Hot Runner System:

Heated Channels: The plastic is kept in a molten state within the runners, reducing material wastage.

No Sprue/Runner Waste: Because the plastic stays molten, there is no need for trimming excess material (sprue or runner) after molding, reducing post-processing time.

Faster Cycle Times: Without the need for cooling and re-heating the material, hot runner systems allow for faster production cycles.

Consistent Part Quality: Uniform temperature control ensures even filling of cavities, improving part consistency and reducing defects like sink marks or weld lines.

2. Cold Runner System:

Unheated Runners: In a cold runner system, the material is injected into unheated channels and solidifies in the runner system along with the part.

Material Waste: After each cycle, the sprue and runner need to be trimmed off and either discarded or reprocessed, leading to more waste.

Slower Cycle Times: Because the material cools down in the runner system, the cycle time is longer, especially for larger parts.

Less Complex Maintenance: Cold runner systems tend to be simpler and less expensive to maintain compared to hot runner systems, but they may not be as efficient for high-volume production.

5 Unique Advantages of Hot Runner Systems

Hot runner injection molding offers several benefits that make it distinct not only from cold runner systems but also from other injection molding techniques:

Material Savings: One of the most significant advantages is the reduction of plastic waste. Since there are no solidified runners to trim, the material is utilized more efficiently, especially for high-cost resins.
Higher Efficiency: With faster cycle times, hot runner systems are ideal for high-volume production. They increase throughput and reduce manufacturing time, making them suitable for industries requiring large-scale production.
Improved Part Quality: Consistent temperature control in a hot runner system minimizes defects and ensures better surface finish, color consistency, and structural integrity of the parts. This is especially important in industries like automotive and electronics where precision is key.
Complex Part Designs: Hot runner systems allow for more complex part designs, with multi-gate configurations that can fill larger or more intricate molds. The ability to fill the mold cavities uniformly without cooling problems opens doors to more sophisticated product designs.
Reduced Labor Costs: Hot runner systems reduce post-production labor costs by eliminating the need to manually remove or reprocess sprues and runners, contributing to overall cost efficiency.

Hot runner injection molding is best suited for:

High-volume production: It is a cost-effective solution for manufacturing large quantities of parts where minimizing cycle time and material waste is crucial.
Precision parts: If the application requires high-quality parts with fewer surface defects and tighter tolerances, the controlled temperature and flow in hot runner systems provide the necessary consistency.
Complex geometries: For parts with complex shapes, multiple gates, or intricate features, the flexibility of a hot runner system enables smooth and even filling

Hot runner injection molding offers significant advantages over traditional cold runner systems, particularly in terms of efficiency, material savings, and part quality. Its ability to reduce waste, speed up production, and handle complex part designs makes it an ideal choice for industries focused on high-volume manufacturing and precision components. While the initial setup cost and maintenance may be higher, the long-term benefits, such as reduced labor costs and improved product consistency, make it a highly efficient solution for many manufacturing needs.

AUTHOR

As a skilled Design Engineer, he specializes in translating innovative ideas into practical, manufacturable designs. With expertise in prototyping, manufacturing processes, and research and development, he creates products that seamlessly blend functionality with user-centric design. His proficiency in Design for Manufacturing (DFM) and Design for Assembly (DFA) ensures that every project not only meets market demands but is also optimized for production efficiency. Known for his meticulous attention to detail and collaborative approach, he is dedicated to driving the development of high-quality products that push the boundaries of design and technology.

Design-Thinking-vs-User-Centered-Design-Srushty-Industrial-design

Design Thinking vs. User-Centered Design: Key Differences and Use Cases

Product Development

We’re back with another interesting blog here on the contrast between Design thinking and User-centered design. I have been asked by many people about the key differences and the use cases. So, let me tell you in detail!

What is the difference between user-centered design and design thinking?

As technology is advancing at a rapid pace, an individual designer or an organization has to keep themselves attentive to design user-friendly updates in products.

Let me brief you on how these are used – Design thinking is useful when we are trying to identify a significant problem and find a solution that will be adopted by people. On the other hand, user-centered design focuses on improving the usability of any tangible or intangible products that the user interacts with. This might not provide a clear distinction, so let’s briefly understand these terms.

Design Thinking (DT)

Design thinking is an approach to identifying a problem at the core level and coming up with an innovative solution. In this process, the designer must think from various perspectives to achieve the end user’s goals. This involves solving a very complex problem with a creative approach to achieve a feasible, viable, and desirable product. This approach might also create a breakthrough in the product development process.

Design thinking is an iterative process consisting of 5 steps-

Empathize – Understand the user behavior and their needs and challenges through observation.
Define – Study the data received and prepare a clear problem statement identified from the user observation.
Ideate – Generate ideas with various methods that could help to achieve the solution.
Prototype – Bring the ideas into the real world with a very frugal prototype.
Test – Test the prototypes built with the users/stakeholders to validate the design, receive feedback, and iterate the process to improve the idea.

User-centered design (UCD)

User-centered design is an approach that keeps the user in the spotlight and meets their needs. Progress in achieving user-centered design is entirely based on iterations focused on fulfilling user requirements.

There are five profound principles of user-centered design –

Early involvement of end users.
A clear understanding of the context.
An iterative process to achieve better user experience.
User-centric approach for product development and delivery.
Constant feedback.

The user-centered design process consists of 4 steps as follows-

Explore – Understand the user needs and the product/service use case.
Discovery – Specify the user requirements/ pain points from the exploration and set up a standard on the process to bring out the best user experience.
Design – Come up with design solutions using user journey mapping, storyboarding, and mockups to define an efficient user flow that solves the problem.
Deliver – Evaluate the ideas with the user and go for improvements based on user feedback.

Ubiquity between DT & UCD

There are a few similarities between design thinking and user-centered design processes.

– Empathizing with the user to understand their requirements, challenges, and behavior by imagining ourselves in their shoes.

– Diversified thinking fosters a holistic approach to achieving better solutions, rather than relying on a limited set of opinions.

– Turning the problems into opportunities, the innovative solution lies down in the problem itself.

– Experimenting more by involving the stakeholders is an efficient way to identify mistakes and learning from them could help in improving the product value.

– The iterative process helps to fill the gaps found in the evaluation stage of product development.

Polarities between DT & UCD

There are a few variations too between design thinking and user-centered design processes.

Majorly, UCD involves the users from the initial stage and throughout the development process to focus on improving user experience whereas Design Thinking emphasizes solving challenging problems with creativity and innovation.
UCD is very much for designing a production/solution for a specific audience while design thinking can be used to break the ice to solve a problem in organizations, communities, policies, etc.

“Usability is about the people and how they understand and use the product and it is not about the technology” – Steve Krug

Hope you had a good read here and I’ll catch up with you with more exciting things about Industrial Design and the design process next week.😎

Keep creating beautiful products people.🤟

If you have any needs, reach out to us, we are here to bring your ideas to life!

AUTHOR

6 Must-Know Industrial Design Trends -srushty PD

6 Must-Know Industrial Design Trends in 2024

Product Development

Industrial design has been evolving with the advancements in humankind and technology. Blending creativity and functionality has always been an exciting challenge that meets the user’s perspective.

The design trend has been changing along with this evolution in our lives. Now let us dive into some of the recent and upcoming industrial design trends –

1. Human-centered design

Human-centric design has always been in play in industrial design considering emotions, ergonomics and many other factors in designing a successful product, as the needs/ requirements change with time – innovation is essential in Industrial design. This can be enhanced with deep design thinking and understanding of the user, which helps them to use the products intuitively by avoiding confusion in understanding the exact function of the particular product.

2. Sustainable design

With rising concerns of global ecological damage, addressing sustainability in design is necessary as the requirements are never quenching in our lives. To cut waste, reduce the product footprint and balance the circular economy, industrial designers must explore eco-friendly materials and energy-efficient manufacturing processes. With this responsible sense, the design process can lead to a timeless design of a product where the user/consumer absolutely loves the product and doesn’t throw it away to add up the waste.

3. Minimalist and functional design

Minimalism in a design can remove unnecessary clutter such as some features, materials etc. that can be avoided to enhance the product value. Focus on absolute simplicity, clean lines and elegance the user experience is also emphasized along with pleasing aesthetics and intuition. Upcoming product designs could focus on multi-functionality such that a single product can serve multiple requirements.

4. Smart and connected products

Technology has been occupying our daily lives exponentially is an undoubtful statement. The trends in technology have been also evolving with many things such as IoT, quantum computing, blockchain to the recent wave of AI in our environment. This brings up an integration of technology with the products, and devices that we use in our daily lives. From smart devices to wearables the products are becoming more user friendly keeping us well connected and offering efficient functionality.

5. AI integration

Another feather in the design trends is AI integration. The integration of AI in industrial design enhances opportunities for customization and user interaction. This technology helps us in analyzing the vast amount of data which could be a precious asset to design personalized user experience in products. This Is leading the industrial design industry in a profound way to create marvellous experiences to the user through functional enhancement and better human-technology-product interaction.

6. Bio-inspired design

Inspiration in Industrial design is a soul in itself that pushes us to solve challenging problems with creativity and innovation. The inspiration from our biological environment helps us to create some breakthrough solutions. A quality that designers must have is attention to detail can mean in form, functionality, and factors of the product, with technological advancements and learnings from our ecosystem we can design products with innovative materials and structures giving freedom to the power of imagination. This has made us solve the challenges in sustainable design too.

I’ll be back with more exciting things about Industrial Design soon. If you have any needs reach out to us, we are here to bring your ideas to life!

AUTHOR

What is a digital twin? How you can adapt it to your engineering project

Product Development

Have you ever wondered how companies predict equipment failures or optimize production processes without breaking a sweat? Enter the digital twin. A digital twin is more than just a static model. It’s a virtual, dynamic mirror of real-world systems, designed to capture every detail and behavior of the physical asset it’s replicating.

The concept might sound futuristic, but it has its roots back in the 1960s. NASA was the first to employ a version of the digital twin, using it to simulate the Apollo missions, particularly when things went wrong on Apollo 13. By using a virtual replica of the spacecraft, engineers were able to assess and rectify the oxygen tank malfunction in real-time. From there, the technology has rapidly advanced and is now shaping multiple industries.

So, What Does Digital Twin Mean?

A digital twin is a digital representation of a physical object or system that mimics its real-time behavior and state. It’s like a virtual version of something tangible; a car, a building, a machine, or even an entire city. This digital model is connected to its real-world counterpart, continuously receiving data from sensors and other input devices to reflect the object’s status, behavior, and environment.

The digital twin provides insight into the object’s performance and can predict outcomes based on various simulations. Think of it as a virtual sandbox where real-world scenarios can be tested without the risks or costs associated with physical trials

A Brief History of Digital Twins

As mentioned earlier, the first iteration of the Digital twin technology came to life at NASA in the 1960s. When engineers needed to understand and fix the oxygen tank failure in the Apollo 13 mission, they used simulations to represent the spacecraft’s condition in a virtual environment. This was a primitive version of what we now call the digital twin.

Since then, the digital twin concept has evolved into a powerful tool across industries, from aerospace to healthcare, driven by advances in data collection, cloud computing, and artificial intelligence.

3 Features of Digital Twins

Real-Time Data Synchronization

Digital twins continuously sync data between the physical asset and its virtual counterpart using IoT (Internet of Things) sensors mostly in industry 4.0.

This means the virtual model is always up-to-date with the latest information about its physical twin.

Simulation and Modeling

Digital twins use advanced algorithms and simulations to predict outcomes and optimize real-world behaviors. Businesses use this feature to test different scenarios, find inefficiencies, and make data-driven decisions.

Feedback Loop

One of the most critical features of a digital twin is the feedback loop. The real-time data captured by the digital twin is used to make real-time adjustments to the physical object, creating a cycle of continuous improvement.

Advantages of Digital Twins

Real-Time Insights

Digital twins provide real-time insights into the performance of assets. This allows businesses to monitor conditions, detect potential problems, and implement solutions before they cause major disruptions.

Predictive Maintenance

By using the data from the digital twin, businesses can implement predictive maintenance. This means they can anticipate equipment failures before they happen and perform maintenance proactively, reducing downtime and repair costs.

Cost Efficiency

Digital twins streamline operations, reducing wasted time, energy, and resources. Companies that use digital twins can make more efficient decisions, ultimately saving money and improving performance.

How Digital Twins Work

Data Collection: Sensors at Work

A digital twin begins with data collection. Physical assets like machines or infrastructure are equipped with IoT devices such as temperature sensors, RFID tags, and motion detectors. These devices gather critical information like temperature, pressure, and vibration.

Data Integration: Cloud Power

The collected data is sent to the cloud for processing and storage. Here, it is organized into data lakes, which can handle vast amounts of unstructured data. This integration allows for in-depth analysis and real-time insight generation.

Modeling: 3D Visuals and Mathematical Precision

Once the data is processed, it is used to create a detailed 3D representation of the physical asset. Algorithms ensure that the model behaves in a way that mirrors the real-world asset, offering accurate simulations.

Simulation and Analysis: Smart Learning

Machine learning algorithms analyze the entire data and make predictions on future performance. Insights from these simulations can help improve efficiency and prevent failures.

Types of Digital Twins

Product Digital Twin

Focuses on individual products throughout their lifecycle. For example, a digital twin of a car engine can monitor its performance in real-time, predicting potential issues like overheating or component failure, allowing for timely maintenance and better fuel efficiency.

Production Digital Twin

Represents an entire manufacturing process. A production digital twin of an assembly line can predict potential bottlenecks and suggest improvements.

Performance Digital Twin

Monitors the performance of an asset in real-time, such as a wind turbine tracking energy production and component health.

Applications of Digital Twins

Digital twin in manufacturing

In manufacturing, digital twins can monitor equipment, predict failures, and optimize production processes. GE Aviation, for instance, employs digital twins to monitor jet engine health.

Healthcare

Digital twins can create personalized models of patients, helping healthcare professionals predict health outcomes and tailor treatment plans. Philips uses digital twins for remote patient monitoring.

Smart Cities

City planners use digital twins to simulate traffic flow, optimize public transportation, and enhance urban development.

Aerospace

NASA employs digital twins for mission planning, such as simulating Mars rover conditions before launching missions.

Digital twins are revolutionizing industries by offering real-time insights, optimizing operations, and predicting potential problems before they arise. Their ability to simulate and model physical objects and processes is invaluable, from manufacturing to healthcare and even city planning.

AUTHOR

The Compliant Mechanism: A Revolution in Mechanical Design

Product Development

Compliant Mechanism is one of the breakthroughs in mechanical design. It is a flexible mechanism that achieves motion through the elastic deformation of its materials, instead of relying on traditional rigid components like hinges or bearings. By using the flexibility inherent in the material itself, compliant mechanisms offer a simpler, more efficient, and often cost-effective alternative to conventional mechanical systems.

But what exactly are compliant mechanisms, and why are they gaining so much attention?

Let’s take a deep dive.

What is a Compliant Mechanism?

Compliant mechanisms differ from conventional mechanical systems in one fundamental way; they use flexibility to achieve motion. Rather than relying on connected rigid components like hinges or pivots, compliant mechanisms bend and flex within a single piece of material.

How Compliant Mechanisms Work?

Compliant mechanisms work by distributing forces through the flexible material, allowing it to deform and then return to its original shape. This movement is powered by the elastic properties of the material itself, enabling it to perform specific tasks with fewer moving parts.

Compliant Mechanism Examples: Paper Clips, Backpack Latches and Electric Switches

Let’s take the simple yet familiar example of a compliant mechanism – paper clip. When you bend a paper clip, it stores potential energy through elastic deformation. Once released, it springs back to its original shape, performing its function without any complicated joints or components

Advantages of Compliant Mechanisms

The compliant mechanism has many advantages over traditional systems:

Simplified Design and Manufacturing: Because compliant mechanisms often consist of a single part, they eliminate the need for complex assemblies, reducing production time and costs.
Reduced Maintenance: Without multiple joints and moving parts, there’s less wear and tear, meaning compliant mechanisms require far less maintenance than conventional systems.
Decreased Friction and Wear: Fewer mechanical connections mean less friction, which can extend the device’s lifespan and improve efficiency.

Comparison with Conventional Mechanisms

Conventional Mechanisms: Rigid Bodies

Traditional mechanical systems are composed of rigid bodies connected by moving joints, such as hinges or bearings. These joints are prone to friction and wear, leading to decreased efficiency and increased maintenance costs over time.

Compliant Mechanisms: Flexible Structures

On the other hand, Compliant mechanisms utilize the flexibility of materials to reach motion. This approach reduces the need for complex assemblies and also improves the device’s overall durability and reliability.

Material Selection for Compliant Mechanisms

When selecting materials for compliant mechanisms, designers typically prioritize:

Popular Materials Used

Common materials for compliant mechanisms include:

Thermoplastics: Such as nylon or polypropylene, which offer excellent flexibility and durability.
Metals: Like stainless steel or titanium, which can be used in applications requiring greater strength.

Material	Fatigue Limit (MPa)	Number of Cycles
Polyethylene (PE)	18	12,000
Polypropylene (PP)	25-35	15,000
Polyetrafluoroethylene (PTFE)	40-50	20,000

Applications of Compliant Mechanisms

Compliant mechanisms are being used across a wide range of industries.

Medical Devices: In surgical instruments or prosthetics, compliant mechanisms allow for precision movements without complex assemblies.
Consumer Electronics: Flexible connectors in devices like smartphones and laptops can reduce wear and tear while simplifying manufacturing processes.
Robotics: Soft robotics, which requires flexible and adaptive movements, heavily rely on compliant mechanisms to achieve smooth and precise motion.

Energy Efficiency in Compliant Mechanisms

Compliant mechanisms mainly focus on energy efficiency. By eliminating the friction caused by multiple moving joints, they reduce energy loss and improve overall system performance.

Kinetic Energy to Strain Energy Conversion

In compliant mechanisms, the energy required to move the device is converted into strain energy within the flexible material. This energy is stored temporarily and can be used to perform useful work, making the mechanism more energy-efficient.

Reducing Energy Losses in Joints

Conventional mechanisms often suffer from energy losses due to friction between joints. By removing these joints, compliant mechanisms reduce friction, resulting in a more efficient transfer of energy.

Challenges and Limitations of Compliant Mechanisms

Compliant mechanisms offer many advantages, but they are not without challenges. Some of the common limitations include:

Complexity in Design: Designing a mechanism that can perform specific functions while maintaining flexibility can be challenging.
Performance Under High Stress: Compliant mechanisms may struggle to perform optimally in high-stress environments, where excessive deformation could lead to failure.

AUTHOR

Suresh is a Mechanical Lead Engineer dedicated to developing innovative solutions in sheet metal and plastic design. Passionate about physics, he focuses on addressing complex customer challenges through modern technologies. As a team leader, he enhances design processes while fostering collaboration and creativity. Committed to continuous learning, Suresh stays updated on the latest engineering advancements to ensure the delivery of high-quality results. His insights and expertise drive our mission to push the boundaries of engineering excellence.

Root Cause Analysis

Key Features of the Device:

The Solution

Lessons Learned

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So, What Does Digital Twin Mean?

A Brief History of Digital Twins

3 Features of Digital Twins

Advantages of Digital Twins

Real-Time Insights

Predictive Maintenance

Cost Efficiency

How Digital Twins Work

Data Collection: Sensors at Work

Data Integration: Cloud Power

Modeling: 3D Visuals and Mathematical Precision

Simulation and Analysis: Smart Learning

Types of Digital Twins

Product Digital Twin

Production Digital Twin

Performance Digital Twin