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How is Finite Element Analysis (FEA) Used for Company Projects in Industry?

Posted on May 27, 2024 by faz_business

Finite Element Analysis (FEA) services offer a platform of virtual simulations used for analyzing the effects of predictable forces on a design. The mathematical-based analysis visualizes when or how a design can fail, materials will deform, assemblies might disintegrate, and a structure can collapse. FEA is ideally implemented during the design phase of a fabricated product to discover rooms for improvement and modify it as necessary. While different industries resort to FEA for various specific purposes, they share the same goals of finding the perfect combination of performance, build quality, and cost.

Consumer goods

Product design companies and engineers in the consumer goods industry utilize FEA to predict components’ future performance and structural behavior before developing physical prototypes. Consumer goods might be built from various materials, such as aluminum, cast iron, steel, metal alloy, thermoplastics, fabrics, and leather, to name a few. FEA works for all materials as long as the user understands their physical properties and characteristics.

Many consumer products can be subjected to FEA simulation. For example, electronics need thorough analysis to determine waterproofing and thermal qualities; furniture pieces require repeated tests to see the load-bearing capacity; shoes and wearable items must meet ergonomic requirements; and children’s toys must be checked for durability and shock-resistance properties. Regardless of the products, FEA can determine whether their designs can withstand physical damage under regular use.

The design for additive manufacturing firms can make well-informed changes if the analysis demonstrates product failures under non-extraordinary loads. Virtual modeling and analysis processes help companies reduce production costs, shorten design cycles, and boost productivity while improving ROI. An FEA simulation of consumer goods is often inseparable from life sciences, especially if the products involve direct human engagement during usage. The simulation might include comfort, stress distribution, support, and fatigue models.

Example case: Foam Bed Optimization

A simulation of a foam bed in an FEA interface helps visualize how the product affects sleep quality. There are at least three variables to consider, including the user’s body measurement, foam material, and foam density. Detailed structural analysis is required to define the ideal thickness and firmness without diminishing comfort. The foam must support the body well enough but remain reasonably soft for a restful sleep. Because the body exerts pressure on the foam, the material must return to its original shape. Based on the design requirements, the manufacturer makes the necessary adjustments per FEA results.

Athletic training

Based on the same user-product interaction principle, design engineering services use advanced FEA software can also simulate the human body to see the effects of specific training programs on muscles and bones. The analysis might also include simulations to measure the effects of repetitive movements—under certain conditions—on soft tissues and joints.

Example case: Elliptical Trainer Linkages Design

One of the main points of an elliptical trainer is to provide the same exercise routines as walking, running, and stair-climbing without the typical excessive pressure on the joints. That said, not every cross-trainer is created equal. Optimization in machine exercise should be based on how it impacts the human body during usage. Suppose a cross trainer is designed for people with knee injuries to stay fit. Unlike most machine exercises, the purpose-built training equipment must accommodate users’ disadvantages.

For instance, the engineering design services company may design better fluidity and lightweight rotational movement on the machine’s linkage. FEA helps determine the exact extent of pressure and force required to utilize the equipment properly without causing further harm to users.A similar method is possibly applied to applications like physiotherapy. FEA-based human body simulations might greatly assist doctors and physical trainers in planning an effective exercise routine to treat patients still recovering from injuries.

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Medical research

Although the design process of training equipment might be listed under the medical research category, they are intended for devices or products outside the human body. On the other hand, the following applications highlight the practicality and usefulness of FEA for designing models meant to replicate actual organs.

Example case: Knee Biomechanics

Direct interoperability with CAD software used by medical device design & development services allows FEA tools to analyze objects of any source, including models generated from a CT scanning process. A three-dimensional reconstruction of a CT-scanned image makes for a comprehensive reference to study the prosthesis design. For example, a reconstructed scanned model of an injured knee clearly visualizes the organ’s musculoskeletal biomechanics.

Surgeons can use FEA simulation to determine the correct motion range of the femoral component. If TKA (Total Knee Arthroplasty) surgery is deemed necessary following the simulation, the prosthesis can be designed for individual patients based on their activity level, weight, age, and general health.

Example case: Dental Implants

In dentistry applications, FEA provides an in-depth look into dental implants’ surface structure and geometry. The simulation helps companies understand the material properties of an implant and how living bone tissues will respond to the applied mechanical force. Detailed geometrical analysis can predict adhesive strength and determine the optimum tightening torque to improve the success rate.

Example case: The Living Heart Project

In collaboration with the FDA, Dassault Systèmes and a massive group of leading cardiovascular researchers are on a shared mission to develop a simulated 3D heart model. The project is at the cutting edge of medical research, with a massive potential to deliver a groundbreaking study in developing new cardiovascular treatments and devices. A highly accurate simulation of a living heart aims to reduce the number of risky real-world clinical trials when designing a cardiovascular device while still ensuring efficacy and safety.

External medical devices

External medical devices’ design and manufacturing processes also benefit significantly from FEA. Such devices are much less sophisticated than implants or pacemakers but equally applicable to improve patients’ comfort during treatments and recoveries. Among the common examples include:

Wheelchairs

As simple as a wheelchair may seem, the equipment should be an over engineered design piece. The engineering design expert must keep in mind that it needs to be durable and comfortable, but also practical and easily maneuverable. Throughout its helpful lifetime, a hospital wheelchair is quite possibly used by hundreds of people with varying weights, heights, and health conditions. An FEA analysis of the material and mechanism will lead to a versatile and heavy-duty design.

Transfusion machines

FEA simulation of blood flow through a pipe assembly is used as the basis for the design of platelet separators or transfusion machines of all sorts. In a typical simulated analysis, engineers perform an A/B study to examine the mechanism of two pipe assemblies and determine the most effective configurations to prevent blood clots, undesired flow rates, and turbulence. In addition to structural analysis, the simulation involves the computation of fluid dynamics.

EMS cots

The primary design considerations for an emergency service cot are load-carrying capability and lightweight components. While materials like carbon fiber and titanium are known to have the two characteristics, they are still too expensive for most emergency services. A cot is not designed by finite element analysis experts to be carried or lifted but is intended to help transport patients from one point to another; apart from material considerations, the locking mechanism should also be easily deployed and released. FEA simulation is expected to lead to the development of a reliable, affordable solution.

In each case, virtual prototyping and simulated performance/usability tests open the doors for medical device manufacturers to design products that improve patients’ comfort and health. Thanks to CAD and FEA, minimum development costs may translate to affordable yet quality devices in the future.

Automotive industry

Automotive design & engineering services design a modern car to be equipped with numerous advanced electronics and moving components. It is also made of many materials constantly exerting forces on each other. Since every assembly requires a thorough assessment for reliability, performance, and quality in a cost-efficient fashion, FEA finds it one of the most significant applications in the automotive industry.

Solid and rigid materials deliver a durable design, whereas lightweight assembly can improve speed and performance. At the same time, the higher-performance engine often generates noise and vibration that might compromise comfort. Modern combustion engines rely heavily on liquid coolant and air to keep the temperatures within a safe range and maintain ideal working conditions. Nearly everything about FEA, from structural and thermal analysis to buckling and computational fluid dynamics, is fundamental in the development of a car design.

FEA also plays a vital role in determining a vehicle’s crashworthiness. A simulation of a crash—or impacts from multiple directions—can help engineers build a dependable safety system, including harnesses and airbags, to minimize the risk of injuries to occupants in the event of accidents.

Civil and architectural industries

Commercial & residential architects and engineers utilize 3D CAD modeling and FEA analysis to create building plans. In addition to ensuring a safe construction process, the simulation tells the architects and engineers whether the finished project can withstand various environmental conditions and topographical issues in the future. Detailed analysis can predict deterioration and the extent of damages to a building’s components under given conditions; based on the information, the building owner or management should be able to set a maintenance schedule to prevent expensive repairs.

How Cad Crowd can assist

Discover the intricacies and potential of Finite Element Analysis (FEA) as it redefines project management and outcomes in the industry. Delve deep into the transformative capabilities of FEA, reshaping how companies tackle complex projects and ensuring optimal results. Equip yourself for the future now and gain an edge over your competitors. Contact us for a free quote, and let Cad Crowd assist you in mastering FEA for your industry ventures.

The Cost of Hiring a Mechanical Engineering Contractor vs. Full-Time Salaried Employee

Posted on April 2, 2024 by faz_business

In some situations, hiring an independent mechanical engineering contractor is better than hiring a full-time salaried employee with the same qualifications. However, employers must understand the difference between full-time and contract workers to determine the best hiring decision. Since most of the distinctions affect the employer financially, refer to the “employee status” classification established by the Internal Revenue Service.

In general, hired contractors are also your employees as they provide services for you but are not formally part of your company. Contractors pay their taxes on the money received for services provided. Alternatively, full-time salaried employees are part of the company’s in-house team. As their employer, you are responsible for overseeing their performance and work conduct and legally handling the withholding and reporting of their taxes. The following classification description can serve as a valuable reference to prevent overpayment, errors in distinguishing between these categories, and the potential incurring of substantial legal penalties.

Independent contractors

For the sake of simplicity, think of an independent contractor as another company. The employer pays for the services provided, whether on a one-time project or an ongoing basis, but the contractor remains independent of your business. A contractor must not abide by your company’s day-to-day operations and will perform the commissioned duties without strict supervision.

Depending on the terms of the agreement, the contractor may never need to show up at the office. The person can do the job from a separate location. For instance, when hiring a freelance finite element analysis & FEA engineering services consultant, the entire task is conducted through computer simulation, and the resulting data is swiftly transmitted as a digital file, eliminating the need for a physical office presence. The work can start immediately once the employer and the contractor agree on the project parameters (including job description and fee). Unless otherwise noted in the agreement, contractors are aware of the following responsibilities:

File and pay taxes (local, state, and federal) on the payment received from the employer
Supply the tools and equipment necessary for the completion of the project on their own
Have their insurance needs covered
Invoice the employer
Expect only to receive payment as stated in the agreement

When an employer and a mechanical engineer sign the contract, it is safe to assume that both parties understand and accept all terms mentioned in the document. In addition to the project brief and payment schedule, the contract may include clauses about deliverables, project milestones, deadlines, and revisions, to name a few.

Full-time employee

The IRS will classify a worker (who provides services for your business) as a full-time employee if you are legally allowed to dictate when, where, and how the person should perform their duties. In other words, the employer must continually direct, supervise, and oversee how the work is done. Another big difference between a full-time employee and an independent mechanical engineering contractor is taxation. The employer is required by law to report the taxes on the employee.

There are three criteria based on which the IRS classifies a worker as a full-time employee:

Financial control: the employer is responsible for payroll taxation (including Social Security and Medicare) and determines paid leave as well as vacation
Relationship: the employee is involved in ongoing business relationships with clients or customers and co-workers
Behavioral management: to a certain degree, the employer may decide the work schedules and methods performed by the employees

Full-time employees most likely work at the location listed as the company’s address. The company makes available the tools and supplies necessary for the employees to perform the duties assigned. Employees are entitled to wages, workers’ compensation insurance, and overtime. The company is also responsible for fringe benefits like retirement plans and health insurance.

Cost of contract workers

Suppose you must hire a freelance mechanical engineering service with the same qualifications as a full-time employee to do the same services. In that case, the hourly rate is likely higher for the former. However, whether or not the contractor costs less in the long run depends entirely on the business needs.

The typical payment process for a contractor differs from the conventional payroll model. A contractor may accept a lump sum, a percentage of the project’s cost, or an hourly rate payment schedule. Regardless of the methods used, the procedure is quite simple. An employer and the hired contractor agree on the project parameters explicitly mentioned in the signed contract, including the scope of work and salary. The payment is made once all the job requirements are met. Mechanical engineering may ask for an upfront deposit or a portion of the total wage as a retainer. Generally, both parties fulfill their roles in the agreement; the contractors get the job done, and the employer provides the compensation. Although you don’t have to handle the taxation requirement for the contractor, you are still required to supply Form 1099 for the payments made.

Cost of full-time employees

An employer controls a full-time employee’s payment schedule and work performance, as well as the administrative details of the taxation. Salary employees are paid a set amount regularly per period, such as monthly, bi-weekly, or weekly. They receive overtime pay for any day they work longer than the scheduled hours. If the duties for the day are completed quicker than expected, they receive the full salary nonetheless. Hourly employees use a timesheet to log the hours worked. The wage equals the hours spent working. Either way, the paychecks are given weekly or monthly.

The employer withholds a portion of the employee’s salary for taxation and benefits purposes. The employees have agreed to authorize the payment of taxes with each paycheck. They can only worry about taxes at least once the time comes for filing tax returns, usually in April each year.

Extra Cost

There are at least three types of indirect costs associated with hiring a full-time employee:

Fringe benefits: payments for retirement plans, healthcare, paid leave, and worker’s compensation
Administrative: expenses attributed to accounting fees, legal fees, and administrative workers’ salaries
Overhead: the business operational cost that cannot be attributable to a specific project, like office supplies, computer maintenance, hosting services, utility bills, and office rent.

According to Clarity 2022: Government Contracting Industry Study compiled by Deltek, the median percentage values for the indirect costs are 30% for fringe, 22% for general and administrative, and 25% for overhead. Cumulatively, the values equal to (1 + 0.3) x (1 + 0.22) x (1 + 0.25) = 1.98 cost multiplier.

Cost comparison

Even if a mechanical engineering contractor and a full-time employee have the same rate of $60 per hour, the total expense incurred for the latter is more significant. Here is a simple breakdown of the calculation:

Employee Status	Hourly rate	Work Hours per Week	Week	Annual Work Hours	Annual Salary	Cost Multiplier	Total Cost
Contractors	$60	40	52	2080	$124,800	1	$124,800
Full-time	$60	40	52	2080	$124,800	1.98	$247,104

Using the median rate for the indirect cost (multipliers), a full-time employee costs almost twice as much as an independent contractor or nearly double the base salary. Unless the project runs for an entire year, the cost of hiring a contract worker can be much lower. However, every business has many long-term projects in which workers require close supervision. Only some mechanical engineering contractors can replace the equivalent full-time employee. As a company grows more prominent, it is not feasible to keep hiring mechanical engineering contractors for new product design services, prototype design engineering services, oversee a manufacturing process, or investigate equipment failures on behalf of the employer.

Payrate

Mechanical engineering is a high-paying profession. The Bureau of Labor Statistics (BLS) states that the average annual salary of a full-time mechanical engineer in the United States is $95,300 or an hourly rate of $45.82. The wage varies widely among different industries. For example, a mechanical engineer working in metalworking machinery manufacturing earns around $40 per hour. Still, an equally qualified professional hired by a crude oil company is paid an hourly rate of between $60 and $75. Sitting in the middle includes the architectural and engineering services industry, which offers an average hourly wage of $48.46, and R&D services, with an average pay of $54.78 per hour.

On the freelancers’ side, a mechanical engineering contractor may cost between $50 – $80 per hour in the United States and Canada. A professional with an experience level of more than ten years in the industry may charge between $100-200 per hour, depending on the scope of work. If the professional is based outside North America, you will likely get a lower rate (but not necessarily a better deal). For instance, the typical hourly rate for a freelance mechanical engineer in India goes from $30 to $50.

Mechanical Engineering Hourly Rates

Location/Experience Level	Industry or Category	Average Hourly Rate
United States	Overall Average	$45.82
United States	Metalworking Machinery Manufacturing	$40
United States	Crude Oil Industry	$60 – $75
United States	Architectural and Engineering Services	$48.46
United States	R&D Services	$54.78
United States & Canada	Freelance (Entry Level)	$50 – $80
United States & Canada	Freelance (Over 10 Years’ Experience)	$100 – $200
India	Freelance Mechanical Engineer	$30 – $50

This table provides approximate information on hourly rates in the field of mechanical engineering. These figures can vary based on individual qualifications and specific job requirements.

How Cad Crowd can assist

Cad Crowd offers services tailored to both short-term projects requiring specialized skills and long-term strategic initiatives. Utilize the expertise and adaptability of our independent contractors to effortlessly and efficiently manage complex projects.

Connect with us to find out how independent contractors can bring value to your business. Get expert guidance and make the best hiring decisions for your company’s unique needs. Get a quote now.