Consumer Products

Manufacturers are under pressure to launch new products to market more quickly while adhering to demanding consumer expectations and warranty requirements. Our engineering simulation and reliability engineering capabilities help speed up product development while managing the risk of failures.

Consumers expect new products with more technical features at lower prices. To meet this demand, engineers need to:

  • Increase innovation
  • Reduce time-to-market through less prototype testing
  • Minimise material, out-sourced component and manufacturing costs while achieving warranty targets.

Modern electro-mechancial devices mean that product design often involves fluid flow and electrical/electromagnetic considerations in addition to structural integrity. Our Ansys Discovery easy-to-use multiphysics software is one solution for fast virtual prototyping, including optimisation.

Alternatively, we support both established product developers and start-up innovators through our simulation consulting services.

Wilde worked closely with Willerby on new product development (Courtesy: Willerby Holiday Homes Ltd)
Wilde worked closely with Willerby on new product development (Courtesy: Willerby Holiday Homes Ltd)


Typically, our structural mechanics capabilities are called upon to validate consumer products are fit for purpose. We have experience investigating abuse load and fatigue issues, including drop tests, to satisfy any regulatory requirements.

Stacking load results of plastic lidded box (Courtesy: Mergon)
Stacking load results for plastic lidded box (Courtesy: Mergon)

Our manufacturing simulation solutions help companies reduce costs while maintaining quality. In particular, with the wide use of plastics, we support companies with Moldex3D software and services to check for any potential surface blemishes & weld lines during moulding and identify any tooling or process improvements to increase throughput. Similarly, our bulk and sheet metal forming capabilities help to minimise production quality issues.


Improving camera lens cover roundness through CAE (Courtesy: Moldex3D)
Cold forming extrusion of plumbing component (Courtesy: IMI Yorkshire Fittings)
Cold forming extrusion of plumbing component (Courtesy: IMI Yorkshire Fittings)

Often consumer products include electronics that can suffer from overheating. Our CFD-based thermal management capabilities help our clients develop cooling design and component placement strategies to avoid such reliability issues.

More generally, our Design for Reliability software and services, including FMEA and Weibull life data analysis, help high volume manufacturers minimise the risk of costly product recalls. Our Gap Analysis services have helped identify areas for improvement within existing reliability programmes, while our ReliaSoft tools accelerates adoption of reliability methodologies. Recent consulting projects include reliability assessments and warranty predictions for domestic heating boilers.

We are increasingly implementing closed-loop FRACAS systems to enable clients to keep track of test and field failures, implement effective recall plans and avoid next generation products with identical failure modes.  Consumer electronics is a particularly fertile area for reliability improvement through standards-based analysis and theoretical support with accelerated life testing.

Reliability analysis (Courtesy: Pace Limited)
Reliability analysis (Courtesy: Pace Limited)


We have worked with over 50 companies involved in consumer products, including:

  • Corgi Classics Ltd
  • Domino UK Ltd
  • Dyson
  • i4 Product Design
  • Ideal Boilers Ltd
  • Mergon
  • Pace plc
  • Vestel
  • Willerby Holiday Homes

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