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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)

Clients

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

The main driver for us is speed of delivery not cost. Wilde Analysis gave us expert advice in a very tight time frame. This meant that we had confidence to move forward quickly with the reworked design and potentially make massive savings in our tooling process.

Orangebox

We were very impressed with how well the process went. Compared to our previous experience of product development / FEA with a prior company, we felt that the process with Wilde was much faster, with results expertly presented and proven to be accurate.

Mergon International

Reliability engineering is becoming ever more important, particularly with extended warranties. It was good working with a tutor who took the time to prepare training material from our own generated data. We will find the software particularly useful.

Ideal Boilers

... Willerby has worked closely with Wilde Analysis on new product development. The work has included in depth FEA and part optimisation studies relating to new product developments.... The work has resulted in excellent opportunities to reduce component part count and material content. Due to the success of this partnership, it is highly likely that further studies will be conducted between the two organisations going forward.

Willerby Holiday Homes

Very useful [ReliaSoft] tools to conduct reliability analysis.

Dyson

Resources

Testimonial Video
Partner Case Study
Partner Case Study
Partner Case Study
Wilde Case Study
Wilde Case Study
Partner White Paper
Partner White Paper
Overview Video
Webinar Video
Overview Video
Overview Video
Webinar Video
Webinar Video
Partner Case Study
Partner White Paper
Wilde Case Study
Wilde Case Study

How Can We Help?

For more information or to arrange an informal, no-obligation discussion on your requirements, please complete the form opposite or contact us using the details below.

From an initial phone call we can often give you an idea of price and time scales.

With subsequent details, we can then send you some solution ideas, scopes of work and a formal quotation.

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