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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The Power of Modern Technologies in Reverse Engineering & Product Development

In today’s industrial landscape, reverse engineering has become an indispensable discipline for understanding, improving, or recreating the design and functionality of existing products. Thanks to advanced technologies such as 3D scanning and laser scanning, this process is now more precise, faster, and more reliable than ever before. This article explores how these technologies are transforming modern product development.

The Cornerstone of Reverse Engineering: 3D Scanning

The first and most critical step in any reverse engineering project is transferring the physical object into the digital world with flawless accuracy. This is where 3D scanning becomes essential.

Measurements that would traditionally take days—or even weeks—can now be completed within minutes using a 3D scanning device. By projecting structured light or laser beams onto the surface of an object, the device captures millions of data points, generating a detailed point cloud. This point cloud forms the foundation of the object’s digital twin.

Capable of capturing complex geometries and freeform surfaces, 3D scanning dramatically reduces the time required to understand the design and is an irreplaceable tool in reverse engineering workflows.

Precision Redefined: Optical Scanning & Laser Scanning

Optical and laser scanning represent high-precision forms of 3D scanning. These systems operate with micron-level accuracy, capturing even the smallest surface nuances.

This degree of precision is critical for reverse engineering in industries such as aerospace, automotive, and medical devices, where even slight deviations can impact performance and safety.

A powerful and precise optical/laser scanning system eliminates bottlenecks during data acquisition and has become an integral part of modern quality-control processes. For this reason, advanced optical and laser scanning equipment is now considered essential in any high-tech engineering environment.

Workflow Integration & Product Development

Reverse engineering is not merely a duplication tool; it is a powerful mechanism for innovation and product development.

Digital data obtained through 3D and laser scanning is processed in CAD environments, allowing engineers to improve existing designs, customize features, or create entirely new products. For instance:

This represents the essence of strategic product development. Today, a competitive product development process requires the integration of these digital tools at its core.

Our Approach

Reverse engineering has reached a new dimension thanks to the speed and accuracy provided by 3D scanning and laser scanning technologies. These tools allow engineers and designers to digitize the physical world flawlessly and innovate freely within digital environments.

Whether the goal is to streamline the production of an existing component or analyze a competitor’s product to design a superior alternative, these technologies form the backbone of intelligent product development. A well-structured approach to reverse engineering and product development positions companies one step ahead of the competition.

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In addition, with this system, we minimize measurement errors that may arise from the person making the measurement, thanks to our training and procedures. We provide services for precise, high quality and detailed measurements at affordable costs.

3D Mobile Measurement and Quality Control

These systems are primarily suitable for products and parts larger than 1 meter and smaller than 30 meters. The system can measure all kinds of materials and surface forms. The main criterion is that the product does not undergo deformation during measurement.

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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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Defne Engineering has started to provide services to its customers faster, with higher quality and at lower costs, with the new software it has started to use in optical scanning and Reverse Engineering (Reverse Engineering). With the help of CATIA V5 software, which it acquired as a new investment, it started to carry out reverse engineering projects in the CATIA environment.

Reverse Engineering Study in CATIA; Helmet Modeling and Modification:

The work carried out together with the manufacturer on new models upon the request of the manufacturer regarding occupational safety is briefly summarized below. The company has prepared a model for the new type of helmet it wants to develop. A new form was created by covering the hand-prepared model with plaster and model material on a standard helmet. The created form was considered together with another type of helmet model currently produced by the manufacturer, and the project was started to create a new design by combining the popular parts of these two different types of helmet. In this project, which started by considering two different helmet types, the stage (spur) above the second model will be added to the first model in line with customer requests, based on the first model, and production will begin with the new model. However, since the model will be produced by the plastic injection method, the computerized design of the new product will be completed in the CATIA program, taking into account the mold design required for the production of the part.

Preparatory Procedures:

There are a number of preparation processes that must be applied first in solid-surface modeling works from measurement data (STL). By performing these operations, problems that may be encountered during the modeling phase are minimized.

First of all, the STL data obtained as a result of optical scanning should be cleaned from unwanted mesh parts that do not belong to the model, and the separated mesh parts remaining in the air should be deleted. Then, the mesh parts that are topologically incorrect (non-manifold, crossing face, redundant face) should be corrected. The holes in the data should be closed, if necessary, the data should be smoothed and decimated within tolerances and placed on an axis set suitable for modeling.

CAD Modeling in CATIA

After the preparation processes mentioned above, the STL data is ready for modeling with the help of the Reverse Engineering module in CATIA.

Unlike modeling from scratch, modeling from STL data is a more difficult process in terms of both time and effort. Tolerances and changes determined by the customer make this process even more challenging. In addition, situations that require high surface quality, as in this project, require more patience, attention, experience and knowledge.

In modeling studies from STL, the following modules of CATIA are mainly used in terms of the operation of the process:

STL data imported with Digitized Shape Editor can be subjected to the above-mentioned preparation processes with various tools in this module, and can also be made ready for modeling with the help of external software. In this project, external software was used to carry out the preparation processes.

In the Quick Surface Reconstruction module, curves such as Section Curve, Feature Curve, 3D Curve and main Primitive or Freeform surfaces are directly obtained via STL. These curves and surfaces can be used directly in modelling, or they can also serve as a reference for new curves and surfaces to be created. The tools in this module are also used to determine trim lines and boundaries. In this project, the curves and surfaces taken from this module were used as references to determine the form of the model, trim lines and various boundaries.

In Generative Shape Design modules, new and higher quality surfaces are created from reference curves and surfaces taken from QSR.

This is the most time-consuming and challenging part of modeling projects from STL. The biggest factor that makes this process difficult is that these created surfaces fit within the tolerances of the STL measurement data (low measurement deviation) and that the surface and surface transitions are very good. Getting an accurate and acceptable result is possible with trial and error. Therefore, it may be necessary to try different surface commands many times by entering different parameter values.

When the desired results are obtained, the surface modeling is tried to be finalized through the necessary surface operations (such as split, trim, join, etc.).

The created surface model is made solid in the Part Design module. After this stage, other features of the physical model (Dress-up features) are added and the model is brought to its final form.

In the first stage of this project, the modeling of the first type of helmet was done using the modeling method outlined above, in addition, the stage above the second type of helmet was added to the model in line with customer requests.

Completion times for STL modeling projects, which are longer and more laborious than other modeling processes, are generally in days. This project took approximately 2 days to complete. The finished version of the model can be seen in the pictures below.

Quality control

Highlight and Environment Mapping Analysis tools were used to see the quality of the surface of the created CAD model. The results are seen in the pictures below.

Highlight Analysis compares the angle between the surface normals and a direction specified by the user. With this method, the continuity in surface transitions and connections is checked.

Highlight analysis

In surface analysis with the environmental mapping technique, a picture is placed on the model and deformations in this picture are observed. The lack of deformations and the smooth appearance of the picture indicate the surface quality. Preferring curvature continuity while modeling will provide better results from this analysis as it will give smoother surface transitions.

The control procedures listed above were used not only at the end of the modelling, but also during the modeling process, and these tools were used to check whether the created surfaces reached an acceptable level.

After all the modeling studies, as a final stage, the measurement control of the CAD data resulting from the reverse engineering work carried out in CATIA with STL data is carried out. In this way, it can be seen dimensionally how much the model deviates from the STL data.

In backward engineering or reverse engineering studies, CAD modeling studies were carried out based on the point clouds formed as a result of 3D measurement and optical scanning. In CAD modeling, the main principles, modeling stages and control method of the RE2 package, the reverse engineering module of the CATIA program, are briefly explained.

This article was published in March 2008 and you can find the publication link below.

You can review it from the published link.

This study, which is one of the first published examples of reverse engineering projects, has become a reference for many people carrying out localization studies.

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What are product performance benchmarks  ?

Product performance benchmarks (also referred to as product benchmarks) are reference points used to compare your product with others. As with other areas of comparison, percentiles are often used to describe how well (or how poorly) your product performs on certain Key Performance Indicators (KPIs) relative to products of similar size and industry. Key Performance Indicators (KPIs) are critical indicators of progress towards an intended outcome. KPIs provide a focus for strategic and operational improvement, create an analytical basis for decision-making, and help focus attention on what matters most. Let’s take a look at why Benchmark is important in the Product Development Process.

Why is product benchmarking important?

For product comparison to be useful, there needs to be meaning behind the numbers. By comparing performance to industry standards, a company can better understand relative performance, including areas where they have a competitive advantage and areas for improvement. For example, how it performs against its peers, what approach competitors use to solve problems, and manufacturing methods are determined in order to form the basis for future improvements in the product. These determinations form the basis of new designs and developments.

As a result, product performance benchmarks are available so companies can identify ways to make their products better. Benchmarking is an important part of the continuous improvement cycle that involves measuring, comparing results to the competition, and identifying improvement opportunities. Before a company can reap the benefits of product benchmarks, it needs to make sure its product organization is effectively capturing product data and measuring the right things.

What metrics are important for product performance comparisons?

Comparison metrics vary depending on the product’s usage area, environmental conditions, product, targeted sector and audience. General parameters that need to be taken into account are;

In the Product Development Process, Benchmark studies play the most important role in creating priority issues in new designs and development studies, determining goals, and defining the problems to be solved. Defne Mühendislik has been consolidating the experience it has gained in backward engineering and design studies since 2005 with benchmark studies for its new designs.

Reference (1) : https://productcraft.com/perspectives/product-management-101-product-benchmarks/

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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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Product development is a definition we make for the updating, localization, development, cost optimization and similar studies of the product that the company currently produces or trades.

The company may want to introduce a product to the market in a new field where it analyzes that competition will be appropriate. At this stage, our company contributes to the creation of competitive and innovative products by examining existing products in detail and catching new trends. We carry out innovative product development projects in different sectors with our knowledge of over 16 years of experience.

In product development studies, possible competitors of the company’s current product are analyzed using the Reverse Engineering method. You can find the details of the reverse engineering study here. The basis of any development work to be carried out, whether on the company’s own product or on rival products, should be based on reverse engineering analyses. In this way, the direction of current products and trends can be determined more clearly.

What is Product Development? What are the product development stages? Before defining these concepts and our company’s approach, what is New Product Development? Let’s summarize briefly.

Product Development – Reverse Engineering

Backward Engineering – Benchmarking

One of the fastest and easiest ways to develop a product is to make various additions and changes to existing similar products. The general opinion about reverse engineering is that it is a “COPY METHOD”. However, reverse engineering is used far beyond copying by digitizing a physical product. Retrospective Engineering is a design and development method used in the development of products or subsystems in many different sectors such as Automotive, Aviation, Defense, Electronics, Energy, White Goods, Cinema.

One of the most widely known examples of Reverse Engineering; During the second world war, British and American forces realized that the Germans had excellently designed gasoline canisters. They adapted these tin cans to themselves by backward engineering. The cans were popularly known as “Jerry cans.”

A similar example in aviation is; Tupolev Tu-4, designated Bull by NATO, was a Soviet piston strategic bomber that served the Soviet Air Force from the late 1940s to the mid-1960s. It was created by backward engineering of the American-made Boeing B-29 Superfortress. Ref( 2)

Benchmark – Comparison

Retrospective Engineering is used to examine competing products and make comparisons. Creating SWOT analyzes of products and subsystems is the first stage of my comparison. The list of features to be used in comparison is created depending on the product’s function, positioning in the market, production method and design. Some of the criteria that should definitely be included in comparisons are; Material, mechanical properties, production method, production processes, maintenance, repair and recycling must be included in the reporting. Product Lifecycle Management, also known as PLM, is also known as Product Life Management Cycle in Turkish. In comparisons, creating the product’s PLM life cycle with all its details will bring sustainable success.

Design-related comparisons can be made in two different ways. The first is redesign, that is, product development work by improving a product and differentiating and updating it for the same purpose. This study includes studies that will enable the evaluation of existing products such as material change, production method and development of product life processes. Another form of comparison regarding design is; These are studies that will be carried out using the forms, production and processes of different products for a completely new product.

One of the best examples of where benchmarking is used in redesign work is the domestic aircraft seat design. In this study, two different model seats were transferred to the computer environment with all their details. All details of the seats, such as material, mechanics, function, ergonomics and production methods, were examined in a computer environment. Through patent research, the works that companies have highlighted and protected in their designs have been examined in detail. The knowledge required to ensure environmental and working conditions was also gained through benchmarking. Existing designs that passed the tests were verified by simulation, and the application of simulations of new concept designs with these principles increased the accuracy to the highest level.

The concept and details of the new design were created with innovative approaches in all details, not just limited to these issues.

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