[ CASE SPECIFICATION // DFM & Manufacturing ]

Industrial Conveyor Bracket Redesign.

Redesigned a heavy-duty conveyor support arm for high-speed robotic assembly lines. Using topology optimization and FEA stress analysis in SolidWorks, material was strategic removed from low-stress zones while reinforcing critical weld fillets.

SolidWorksANSYS WorkbenchGD&T (ASME Y14.5)Sheet Metal Design

01 // ISOMETRIC 3D CAD RENDER

01 // TECHNICAL CHALLENGE

The legacy cast-iron conveyor bracket experienced cyclic fatigue failure after 85,000 cycles under asymmetric dynamic loads, causing unplanned assembly line down time.

02 // ENGINEERING & DFM SOLUTION

Developed a billet-machined rib-reinforced bracket geometry with targeted radius fillets and precision GD&T datum references. Verified static and fatigue endurance up to 2,000,000 load cycles in ANSYS.

03 // MODELING & TOLERANCING HIGHLIGHTS

—Adaptive parametric sketch relations for rapid clearance tuning

—Class-A smooth fillets to eliminate stress concentrations at mounting hubs

—Integrated thread insert counterbores with tight tolerance stacks

TECHNICAL SPECIFICATIONS

Material:7075-T6 Aerospace Aluminum

Yield Strength:503 MPa

Weight Reduction:38.4% (from 4.2kg to 2.58kg)

Max Load Capacity:18.5 kN Dynamic

Manufacturing Method:5-Axis CNC Milling

FEA SIMULATION DATA

Max Stress:142 MPa (von Mises)

Safety Factor:3.54 (Dynamic Load)

Optimization:38.4%

QUANTITATIVE RESULTS

✓Zero field failures across 1,200 deployed units over 18 months

✓38.4% weight reduction leading to lower motor torque requirements

✓Manufacturing unit cost reduced by 22% via optimized 5-axis toolpaths

“

Haris transformed a recurring warranty nightmare into our highest-reliability structural component. His precision in DFM saved us over $140,000 in dynamic downtime.

Marcus Vance — VP of Manufacturing Engineering, AeroLine Automation Technologies