Industrial product design is the discipline of producing functions, sustainability and competitive advantage as aesthetics. One of the most effective ways to achieve these goals is the benchmark approach. Benchmark is not limited to reviewing competitor products only; nature is the most advanced benchmark source with millions of years of testing.

In this article, we take reference to nature-inspired designs and discuss in a summary and focused way why benchmark is critical in industrial product design.

What is Benchmark?

Benchmark is the process of analyzing a product, system or design approach by comparing it with the best examples. The aim is not to copy, but to develop better, more efficient and more sustainable solutions by detecting strengths and weaknesses.

To study how benchmark is systematically implemented in product development processes:
https://defnee.com/urun-gelistirme-surecinde-benchmark-kiyaslama-2/

Nature-Emitted Designs: Powerful Benchmark Examples

Termite Slots – Natural Ventilation and Heat Control

The termite slots have natural air ducts that keep the indoor temperature almost stable. This building is designed to take benchmark, the Eastgate Centre building has minimized the need for mechanical air conditioning. In industrial product design, this approach is a strong reference in terms of passive cooling, air circulation and energy efficiency.

Yalushpine Bird – Fluid and Silent Form Design

The nose form of the Japanese Shinkansen high speed train was developed by taking the benchmark of the seagull bird at the time of entry into the water. In this way, the sound explosion problem has been solved, energy consumption is reduced. This example clearly reveals that the form determines performance directly.

Bee Honeycombs – Light and Durable Structures

Bee honeycombs are known for their hexagonal geometry, which provides maximum strength with minimum material. Today, this structure is used as a benchmark for light panels, carrier structures and housing systems in industrial product design.

Shark Skin – Friction and Hygiene Control

The microstructure of the shark skin makes it difficult to hold bacteria while reducing friction. These properties are used in coating, medical and fluid systems in industrial product design.

Benchmark’s Contribution in Industrial Product Design

A correctly edited benchmark process;

Defne Engineering handles industrial product design together with benchmark, engineering analysis and aesthetic design. Products are compared not only with competitors, but also with the most efficient systems in nature.

For more information:
https://defnee.com/urun-tasarimi/

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Defne Engineering cooperates with universities in joint training. İrem KAYA and Yaren ULUG, our industrial product design students at Joint Education, carried out concept development studies on passive sound amplifiers.

They created a vocal tract concept using different geometries to suit pop and rock sound profiles. Using acoustic analysis software for the sound path, they focused on a few geometries that would increase the sound amplifying feature but would not change the sound frequency.

To find the best sound frequency match, they prepared their design in 3D using acoustic vocal tract analysis software. Acoustic sound path alternatives were produced and tested using the rapid prototype production method. After the test studies, the two models that gave the best results were produced as prototypes using the layered manufacturing method. The designs were planned to be produced by the layered manufacturing method, using new technology that would not be particularly suitable for mass production. Additive manufacturing technology called FDM method was chosen. In this method, molten plastic is poured from one or two units to form each layer in a way that follows 2-dimensional contours. After one layer is completed, the plate moves for the next layer, creating the product in the third dimension. This principle is approximately the same in all rapid prototyping methods. Each layer is produced and another layer is added above or below it. Similar technologies that use light, powder, filament, liquid, plastic, wood, metal and even sand use this principle of additive manufacturing.

The resulting products are subjected to subsequent processes and obtain their final shape and strength using certain technologies. Additional post-processes such as surface treatments, painting and coating are applied to the products that have their final geometric and mechanical properties and are made ready for delivery to the end user. In this study, prototype products exhibit the performances shown in the video below after assembly and painting.
In order for everyone to benefit from our design; You can download the data in STL format from this link on our website so that rapid prototypes can be produced.

Saygılarımızla

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Our urban bus development project with a new concept, which we started with our customer in 2008, has started mass production. The vehicles produced have become more popular than their competitors in the Middle East and Asian markets, especially in Azerbaijan.

Concept, detail and production designs of the front and rear of the vehicle are by Defne Mühendislik Ltd. Ltd. It is another source of pride for us that the vehicle produced by Ashok Leyland was appreciated and put into mass production by an international company with experience in R&D and design, operating in 30 countries. India’s gross domestic product ranks fourth in the world. It is predicted that it will be among the top three countries in 2020. Ashok Leyland, one of the companies that can analyze the Asian and European markets well, says that the domestic designs made in our country; It is one of the companies that can predict that they will find a high market share in the countries where they operate.

The new concept design using Reverse Engineering tools was obtained as a result of our company’s dedicated and intense work on Industrial Product Development, detail design, manufacturability and quality in details. The main carcass structure to be used in the production of the vehicle was transferred to the computer environment with the 3D measurement method, and the concept was developed in accordance with this structure. In vehicle design, 2nd degree continuous surfaces called A-Class were created with the advanced surface modeling method. Mechanical and production details studies were carried out by choosing one of the 3 different alternatives created.

The vehicles exhibited in Busworld 2012 Istanbul, produced in two different lengths of 5.5m and 7.5m, are released to the market as alternative series for different purposes with different interior equipment. The development of products for the domestic sales of the vehicles, which received very positive reactions from the domestic market in terms of body appearance at the Busworld 2012 fair, continues.

Valuation of domestic designs in international markets in our country, where the infrastructure of domestic vehicle production has been established, will form the stepping stones on our country’s path to becoming a design base from contract manufacturing with this and similar projects.

Seeing the traces of domestic designs in foreign markets and contributing to our country’s progress in design and production is a hopeful step for both our company and the domestic industry. Such developments for export are much more valuable than the share gained in the local market. The orientation of production and R&D structuring towards exports is the most important factor that will make our country stand out in the global economy.
regards

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Defne Engineering company has extensive experience in the design and development of mechanical superstructures of electronic products. Its experience in cash registers and payment recording devices, which it had previously developed and used in the market, has been strengthened.

This product, whose concept and mechanical design was carried out by Defne Engineering with our Industrial Product design, Value Engineering studies, has achieved pioneering and leadership in payment recording devices. It was launched as a first in its class.

As a result of the innovation and creativity work carried out with our customers in design and development, the product was released to the market faster, higher quality and more reliable than its competitors. This high quality was achieved thanks to the engineering studies carried out in the design and production stages.

At the product concept stage, ease of service, customer needs, usage environment and modularity were taken as basis. We developed the concept design phase with our customer. A team of different disciplines worked to ensure that the resulting concept kept up with the advancing technology and to ensure that both the mechanical and electronic infrastructure were up-to-date.

The product family, whose design phase was completed, was pre-manufactured using special and classical manufacturing methods for testing and validation studies.

With its electronic and mechanical infrastructure based on the latest advanced technology, it has successfully passed all tests and has been approved.

A first in its sector, the product family has gained sustainable leadership in terms of its quality, safety, reliability, service and durability.

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Defne Engineering Ltd. Ltd. We have been carrying out product design and product development studies since 2005. We have successfully completed more than 7000 product design, product development, backward engineering and benchmark projects for different sectors, especially the defense, aerospace, automotive, white goods and medical sectors.

To carry out new projects in different sectors in areas where we have not worked before; It helps us both create a success story and increase our professional satisfaction. These types of studies; It is a serious source of motivation for us as it adds value to our company’s creativity development and projects.

Another advantage of carrying out different projects from many different sectors is that the creative ideas to be used in new development projects are based on experience.

As Defne Engineering, cover design, development, optimization, testing and prototype production work was carried out for Li-Ion rechargeable batteries that will be used in satellite systems in 2020. These design and development studies for Li-Ion rechargeable batteries with prismatic geometry make energy storage safer and more controllable both in space studies and in different sectors such as electrically powered transportation vehicles, electronics, medical and defense where rechargeable batteries are used.

Since the main criteria of the product design project are environmental conditions in the space environment, there are standards that must be followed in the materials to be used and the products produced from these materials, especially in the manufacturing and assembly processes. These standards are defined by the European Cooperation for Space Standardization (ECSS) and the National Aeronautics and Space Administration (NASA). In addition to these operating conditions, it is a must for the rechargeable battery to be resistant to the additional pressure, temperature, chemical substances and electrical environment that may occur during the functioning of the product, together with its sub-parts. All criteria, from the materials to be selected to the production method and the final product, must meet the main standards and their sub-conditions defined by these two institutions.

It consists of the main plate on the battery cover, anode and cathode pole, mechanical current interrupter system (CID), valve defined as emergency safety valve and sealing elements. The main headings and stages of the work carried out for the cover and lower parts are as follows:

In product design studies, a detailed project plan was created at the beginning of the project. The current plan was updated in the later stages of the project and revisions were made to its details. By adhering to the master plan, the project was delivered on time and with the highest quality.

Figure 2: CID mechanism research

It is necessary to use scientific studies and new approaches in the product design studies where the working environment is space, such as satellite systems, where high technology products are used, and to be verified by physical tests. International scientific articles were searched for previous mechanical designs on the product and its sub-parts, as well as the mechanical properties and production methods of these parts. Both the mechanical systems in which the products perform their functions and the development of the production processes of these products guide scientific studies and articles today. Articles and patents published, especially in China, show that developments on this subject are still ongoing. Patent research, which is the first stage of the design study; Examination, classification and interpretation of both international patents and scientific articles published on this subject were carried out.

Concepts have been created for the mechanical current interrupter (CID) mechanism, valve and terminals in accordance with the battery sizes to be used. Designs were shaped to include mechanical details for a few models selected from these concepts created during the conceptual design phase. At this stage, production methods are formed along with their alternatives.

All materials to be used in the battery cover must be approved to the standards and environmental conditions defined by NASA. In addition, in order for the materials of some sub-parts to fulfill their mechanical duties, their behavior in the non-linear region in the stress and elongation graph is taken as basis. The material must fulfill its function in this behavior zone but must also be far from the rupture limit. This type of material shows the same mechanical properties within certain tolerances in every production package. In order to ensure that the mechanical properties of the materials to be used in our project are not affected by differences in production packages, materials produced at once were supplied and used in testing and production. Some materials were brought closer to the desired mechanical behavior profile by additionally applying special heat treatments. The same materials were subjected to tensile tests in Kosgeb and the manufacturing companies and stress-strain curve profiles were obtained. These profiles were used in non-linear structural simulation studies to obtain results closest to reality. According to these results, the material geometric properties were optimized to meet the operating conditions.

Figure 3: Bulk tensile test results

In addition to subjecting each component to a computer simulation in the working environment to fulfill its function individually, structural optimizations were carried out on the entire system by examining the integrated product’s response to environmental tests with non-linear analysis. By taking this optimization material properties, production and production processes into consideration, a geometric and mechanical design suitable for mass production has been developed. Thus, the problems that are very difficult to supply or that may occur during the production process due to dimensional tolerance deviations from production have been minimized with the optimization work at this stage.

In the optimization study, details of the production processes were tried to be prevented, such as tolerance accumulation that may occur in the sub-parts during production. The waste rate in production has been tried to be minimized with test productions and apparatus-fixture designs made during the production phase. With production process optimization, waste rates in the production of sub-parts have been improved by up to 70%.

Figure 4: Subsystem analysis with nonlinear analysis

Each part was produced in multiple quantities, taking into account repeatability on mass production machines and conditions, and was first subjected to simple workshop tests and then to environmental tests in an independent testing institution to meet ECSS standards. Sixty percent success rate was achieved in the first tests. Thanks to the improvement of production processes and environments, a 90% success rate of approval was obtained in part-based tests.

Polyphenylene Sulfide (PPS) material was chosen as the sealing element due to its electrical resistance, chemical resistance and mechanical properties. A scientific study was also carried out during this project with the plastic injection method using γ-aminopropyltriethoxy silane-based binder to ensure that PPS remains sealed with aluminum at high pressure and temperature. A side benefit of this study is that the PPS product obtained by domestic production, if used with the developed process, achieved the desired success in ECSS tests.

Figure 5: Schematic representation of the PPS – Aluminum chemical connection

The lithum cell and its box, called jelly roll, together with the battery cover, constitute a unit battery. This product has been subjected to simulation tests with FRF (Frequency Response Analysis PSD (Random Vibration Analysis) SRS (Shock Response Spectrum Analysis) finite element analysis in ECSS-E HB-32-26A standards. The assembled version of the entire system is far from critical values, Real Reporting was created on the basis that the tests should be easily passed.

Figure 6: FRF and SRS results of Li-Ion whole battery

With the experience gained from these tests, the designs and processes of the entire product’s apparatus, fixtures and molds were reviewed, improved, developed and produced. There are 11 sub-parts and more than 33 processes in the battery cover part. Following the successful completion of the physical environment tests of the sub-components of the cover product, assembled production was carried out. Assembled production is subjected to tests at ECSS starts and development processes continue.

Figure 7: Prototype pre-series production

The development and improvement efforts of the battery cover, whose pre-mass production has been successfully completed, continue. The achievements of this successfully completed project, albeit in a different sector, will enable us to achieve much more creative and quality results in our new works. Continuing its work with a center of excellence approach, our company will continue to serve with its developing staff to provide new gains to our country.

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Product design and product development can also be considered as complementary definitions. Our company defines Product Design studies as a process that starts from the concept design stage and includes mass production and even the product life cycle. As for product development, we use exactly what it means in Turkish. In other words, we define design and production focused work such as developing, renewing, and improving the cost of the existing product.

Joint studies on Product Design and product development are primarily research studies in which preliminary information such as market market research, user experiences (UX) and analysis of current and potential competitors will be obtained. If this preliminary information is analyzed correctly, the details and stages of the project to be worked on will be defined more accurately and in detail. These definitions determine what the problems to be solved are. How to solve problems is determined by experience. Working with different sectors enables us to offer creative solutions to problems. High quality sustainable products are developed as a result of patient, detailed work.

Problem Definition and Solving Methodology

The most important success in problem solving is to define the problem in the most accurate way. In order to identify the problems in the most accurate way, field information is analyzed correctly and competitor products are examined and interpreted in detail. Our approach to product design and product development as a problem identification and problem solving methodology gives us the chance to create innovative, long-lasting, reliable products without mass or special production problems.

Problem Definition

Our engineering method for problem definition used in Product Design and Product Development studies is Backward Engineering – Reverse Engineering – studies. The entire infrastructure of the product that forms its identity, such as its physical properties, material, strength, production method, is examined and interpreted. At this stage, our experiences and detailed studies and the comments made form the basis of both design and development studies.

As Defne Mühendislik, all our work is followed until the product goes into mass or special production without any problems. This approach enables us to work together with our customers on all their new projects.

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