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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
Industrial Conveyor Bracket Redesign
3D CAD RENDER // EXPLODED STRUCTURAL VIEW

Engineering 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.

Applied CAD & 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.

Key Modeling & Surfacing 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
ENGINEERING 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
THERMAL & STRUCTURAL SIMULATION
Max Stress / Load: 142 MPa (von Mises)
Factor of Safety: 3.54 (Dynamic Load)
Structure Optimization: 38.4%
Mesh / Analysis Type: Curvature-based Solid Tetrahedral (124,000 nodes)

Quantitative Deliverable 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