Iterating Mechanical Designs Across Multiple Prototype Rounds
Early discovery of failures cuts the real cost of hardware development.
Renata Sokolowski
8 stories
Early discovery of failures cuts the real cost of hardware development.
Different roughness parameters catch different failure modes in service.
Cutting tooling cost and material strength reveal which process wins for mid-volume aluminum runs.
Copper content and stress-relieved temper make 2024 the fatigue-resistant choice for cyclic loading.
Design and shop floor must agree on how to measure each tolerance, or rework and disputes follow.
How to design internal corners, start holes, and slot geometry so wire EDM cuts them right.
When bending sheet metal for enclosures, match the radius to material ductility.
Choose the finish based on function, not looks, or pay for rework.