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COSMOS®

Analysis Guide For Medical Product Designers

SolidWorks Corporation

C O N T E N T S

The challenges of medicalproduct design 1-3

The power of SolidWorks andCOSMOS integration 4

Analysis capabilities 5-9

A G U I D E T O M A X I M I Z I N G P R O D U C T I V I T Y G A I N SI N T H E M E D I C A L D E S I G N I N D U S T R Y.

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How SolidWorks Speeds Consumer Product Design

SolidWorks Corporation

S U M M A R Y

SolidWorks® OfficePremium bridges the gap between industrialdesign and engineering by providing powerful surfacing capabilities, the ability to easily importgeometry from dedicatedindustrial design tools,and the industry’s topmechanical engineeringenvironment – all rolledinto one package. In thispaper, you will learn howSolidWorks software provides a complete modeling environment for taking designs fromconcept to manufacturing.

COSMOSWorks Designer –included with SolidWorksOffice Premium – helps youto determine the stress,strain, deformed shape, anddisplacement of componentsunder operation, in order toavoid field failures.

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you can set the background, lighting, and scenery conditions. You can also com-bine PhotoWorks with SolidWorks Animator to create photorealistically renderedanimations. For example, you can revolve the product 360 degrees on a turntableto see how it looks from every angle, or you can capture the motion of movingparts to show a clamshell-style cell phone being opened and closed.

Integration of the industrial design with mechanical engineering behind a singleuser interface means you can evaluate the mechanical performance of the designat a much earlier stage. COSMOSWorks® Designer – included with SolidworksOffice Premium – helps you determine the stress, strain, deformed shape, anddisplacement of components under operation, in order to avoid field failures. You can also use this tool to quickly identify and solve problems by generatingnew computer models quickly and inexpensively. After determining the exact duty cycle of components, you can often reduce the cost and weight by usinglighter-duty components or by removing material where it isn’t needed. UsingCOSMOSWorks Professional, a separate add-on solution, you can even perform"drop tests" – simply drop the design from a specified height to see if it breaks.

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With COSMOSWorks Professional, you can use the drop test simulation capabilitiesto study the effect of impact on a model that is dropped from various heights.

At a very early stage in the design process, you can use MoldflowXpress – fully integrated with SolidWorks software – to determine the manufacturability of plastic injection-molded components. MoldflowXpress is an entry-level plastics-filling simulation tool that can predict whether an injection-moldedpart will fill based on geometry, injection location, type of material, and processing conditions.

Using SolidWorks software can help you avoid costlymistakes by ensuring thatchanges made anywhere in theprocess automatically updateall product documentation,including parts, assemblies,and drawings.

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Engineering changes typically occur at a release phase. Using SolidWorks software can help you avoid costly mistakes by ensuring that changes madeanywhere in the process automatically update all product documentation,including parts, assemblies, and drawings.

The SolidWorks Manufacturing Network simplifies the process of finding design and manufacturing service providers that use SolidWorks software andwork with native SolidWorks files, thereby avoiding the need for converting or re-creating design files. You can easily find the right supplier on the network by browsing through 21 categories, ranging from a machine shop to an outsidedesign firm, or by searching on keywords.

eDrawings™ is a free CAD viewing and collaboration application that lets youdistribute 2D and 3D drawings to others who can view them – without having to install any software. When you need to determine your design direction, itprovides the perfect tool for simplifying communications among industrialdesigners, mechanical engineers, engineering management, and marketing. A single document contains a compressed version of a 3D model and its associ-ated 2D drawing, as well as animated views and a self-extracting viewer. Therecipient doesn’t need a CAD program, and file sizes are small enough to easilydistribute via email. With eDrawings, you can distribute drawings to customersand suppliers without revealing sensitive design data. Recipients are able toview, measure, and interrogate the drawings with enough detail to verify thattheir specifications are met and to accurately submit quotes for production. You can even add comments that are tracked successively in the history of thedocument as it is passed from person to person.

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eDrawings Professional allows an unlimited number of recipients to mark up your product designs andprovide feedback via email.

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COSMOS®

Analysis Guide for Electronics/ElectricalProduct Designers

SolidWorks Corporation

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Introduction 1

Analyzing at the forefrontof electronics andelectrical produstdevelopment 2

Application area 3

Scope of analyzing 3

Tight integration with 3D 4

“What if” studies 4

Powerful analysis types: 5-6

Assembly analysis 7

3D visualization 8

Design communicationand collaboration tools 8

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COSMOS®

Analysis Guide for Machine Designers

SolidWorks Corporation

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Analyzing at the forefrontof machine designproduct development 1-2

Application area 2

Scope of analyzing 2

Tight integration with 3D 3

“What if” studies 3

Powerful analysis types 4-6

Assembly analysis 7

3D visualization 8

Design communicationand collaboration tools 8

COSMOS ®

W h i t e P a P e r

T h e F u T u r e o F M e c h a n i c a l D e s i g n

SolidWorks Corporation

Using SolidWorks to Overcome the Challenges of Mechatronics Design

S U M M A R Y

Designers of mechatronics products must create highly complex mechatronics systems that successfully integrate electrical, mechanical, and information-processing components. SolidWorks® Office Premium can help you meet the unique challenges of mechatronics design, enabling you to use digital modeling to reduce physical prototypes, improve product quality, and streamline your entire development process.

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the Challenges of MeChatroniCs design

Integrating Simulation and Modeling into the Mechatronics Design Process Much has been made of the positive effects of integrating digital simulation and modeling into mechatronics design, and for good reason—it saves time and money, reduces risk, and results in more innovative and higher-quality products. An example of how this works is seen in the mechatronics synergy that SolidWorks Corporation has fostered with one of its partners, National Instruments. Because of the synergy between these two companies, customers have realized great value when moving from mechanical to electromechanical machine design. By integrating National Instruments’ LabVIEW and NI SoftMotion products with the 3D modeling and mechanics of SolidWorks and COSMOSMotion™ software, this synergy is driving product, process, and business improvement through simulation and modeling.

SolidWorks geometry of an aluminum euro symbol unit for vibration testing, showing suggested accelerometer sensor placements for use with National Instrument’s NI Insight and NI LabVIEW software.

Actual physical aluminum euro structure mounted for vibration mode testing with sensor placement aided by initial placement in SolidWorks geometry analysis.

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h o w s o l i D w o r k s F u n c T i o n a l i T y a D D r e s s e s M e c h a T r o n i c s

the Challenges of MeChatroniCs design

Unlike other computational fluid dynamics (CFD) programs, COSMOSFloWorks combines a high level of functionality and accuracy with ease of use. Fully embedded inside SolidWorks, COSMOSFloWorks is suited for the engineer who needs flow analysis, but is not necessarily an expert in the field of fluid simulation. A goal-oriented approach allows you to gain insight into the performance of a design under real-world conditions. Designed to be extremely flexible, COSMOSFloWorks can be used in a wide range of applications.

COSMOSFloWorks greatly reduces multiple heat studies by testing designs virtually at first, thereby eliminating costly prototypes.

With PhotoWorks™ software, you have the ability to quickly and predictably create photorealistic renderings for presentations and downstream (sales, support, marketing) reuse and repurpose. Additionally, you can present convincing design proposals quickly and effectively, produce virtual material studies, and reduce prototyping and photography costs, thereby bringing your products to market faster.

SolidWorks Routing enables you to quickly design pipe, tube, and electrical routes in mechatronics product designs. For designers of electrical and electronic systems, SolidWorks Routing provides additional timesaving tools for generating cable and harnessing manufacturing documentation. Because it uses the familiar SolidWorks 3D CAD design environment, SolidWorks Routing is fast and simple to use. The routing application and fittings library is fully integrated with SolidWorks, so your routed systems design can be done in the same package as your mechanical equipment design.

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Bringing Innovative Medical Products to Market Faster

SolidWorks Corporation

S U M M A R Y

To succeed in today’s med-ical device manufacturingindustry, product design-ers must not only createinnovative medical prod-ucts but also navigate anincreasingly challengingregulatory environment.SolidWorks® OfficePremium software canhelp you meet this challenge. Powerful partdefinition and industrialdesign tools foster productinnovation while integratedsoftware prototyping andcomprehensive designmanagement capabilitiessupport regulatory compli-ance. With SolidWorkssoftware, you can quicklydevelop and analyze medical devices and components – and bringthem to market faster.

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Having the ability to managemultiple configurations froma single document makes iteasy to apply changes to allof your configurations or tojust those that you select.

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Product Design on an Integrated Platform

SolidWorks Office Premium software automates product design, makes it easyfor you to take a design from concept to prototype, and documents every stepalong the way. Working on an integrated design platform will help you toreduce repetitive design tasks substantially, access analysis capabilities withinthe same environment easily, and create comprehensive design documentationautomatically.

Using configuration management capabilities, you can enter dimensionalparameters in a spreadsheet and use a design table to automate the creationof hundreds of part or assembly iterations in seconds. You can turn features onor off in different configurations and can assign properties – such as material,part name, and cost – to a configuration. Having the ability to manage multipleconfigurations from a single document makes it easy to apply changes to all ofyour configurations or to just those that you select. With these capabilities, youcan greatly reduce the amount of work required and time spent to produce andmaintain a family of products based on a single technology platform.

Having solid modeling and design analysis (finite element analysis, or FEA) inte-grated within a single environment, means you can evaluate design performanceat a much earlier stage, as well as the results used to refine and optimize thedesign, rather than performing these tasks as a final validation check prior toprototyping and production. You can use COSMOSWorks® Designer software,

With the eDrawings tool, you can communicate your design concepts quickly and easily to everyoneinvolved in the design process.

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The SolidWorks Print3D web portal gives youimmediate access to themost effective rapidprototyping technologies in the industry…

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Although advances in display technology have substantially improved its visualprototyping potential, working with an actual physical prototype is still the most intuitive means for reviewing a design. Prototyping and testing prior to trials is also an FDA requirement, and medical product developers need accessto the latest rapid prototyping technologies to keep development on track. TheSolidWorks Print3D web portal gives you immediate access to the most effectiverapid prototyping technologies in the industry, including stereolithography (SLA),fused deposition modeling (FDM), selective laser sintering, rapid injection mold-ing, and 3D printing. By automating prototype development, SolidWorks Print3Denables you to order prototypes in minutes instead of hours.

Engineering changes typically occur at a rapid rate during the product assemblyand testing phase. SolidWorks software helps you avoid costly mistakes byensuring that changes made anywhere in the process automatically update allproduct documentation, including parts, assemblies, and drawings.

The SolidWorks Print3D web portal automatically transmits model data for animmediate quote on rapid prototyping services.

COSMOSFloWorks enabled engineers to determine the optimal design for a new oxygen delivery device.

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SolidWorks softwareautomatically maintains yourbill of materials, so you canexport it as an Excelspreadsheet or in otherformats for use with materialrequirements planning (MRP) systems.

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Manufacturing

Once you have generated, prototyped, and tested your design, SolidWorksOffice Premium software automates production setup and manufacturing.SolidWorks software automatically maintains your bill of materials, soyou can export it as an Excel spreadsheet or in other formats for use withmaterial requirements planning (MRP) systems. This information willhelp you save time and avoid errors during the purchasing process. Thesoftware tracks a wide range of information, such as the manufacturer ofpurchased components, model number, size, and weight. By generating asingle bill of materials for multiple projects with numerous parts, quanti-ties, and configurations, you can speed the transition to manufacturingand can purchase greater quantities at lower prices.

SolidWorks Corporation partners with industry-leading computer-aidedmanufacturing (CAM) software companies to deliver a variety of powerfulCNC programming solutions for milling, turning, and electronic dischargemachining. Since Certified CAM Solutions read native SolidWorks geome-try and are fully associative, your design changes are reflected in the CNCprogram. Certified Gold Solutions also provide single-window integrationwith the SolidWorks model, enabling generation of the CNC programpath within the familiar SolidWorks environment.

The SolidWorks Print3D web portal automatically transmits model data for an immediate quoteon rapid prototyping services.

With PDMWorks, you candocument the reasons formaking design decisions,including analysis and testresults, and can trackrevisions generated at eachstep of the process.

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The SolidWorks Manufacturing Network simplifies the process of findingdesign and manufacturing service providers that use SolidWorks soft-ware. By working with native SolidWorks files, you do not have to worryabout converting or re-creating files. You can easily find the right supplieron the network by browsing through any of 21 different categories, suchas metalworking, machining, injection molding, and sheet-metal fabrica-tion, or by simply searching on keywords.

With SolidWorks software, you can automatically generate a bill of materials, which you canexport as an Excel spreadsheet or in other formats for import into MRP systems.

Regulatory Documentation Compliance

Instead of incurring the time and expense required to manage, archive,and track design documentation in either a manual, paper-based or high-end revision control system, you can cost-effectively automate thedocumentation function with SolidWorks Office Premium software. The SolidWorks Office Premium development environment includesPDMWorks® software, an integrated product data management (PDM)solution that securely archives and organizes multiple versions of previ-ous projects. With PDMWorks, you can maintain a high level of controland manage the information needed for your medical product designwithout resorting to an expensive, hard-to-administer, high-end infra-structure. PDMWorks helps you manage, track, and document theengineering change process throughout the product development lifecy-cle. With PDMWorks, you can document the reasons for making design

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decisions, including analysis and test results, and can track revisions generat-ed at each step of the process. PDMWorks delivers more flexibility than manycompetitive version control systems, so you can define relevant version andrevision schemes.

PDMWorks manages design revisions and automatically captures the history of all revisions.

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COSMOS®

Solid Modeling and Analysis ofMEMS Structures

SolidWorks Corporation

C O N T E N T S

Introduction 1

3D visualization 1-2

Sub-micron featuredefinition 2

Patterns and creation ofpatterns of patterns 3

The power of configurationmanagement 3-4

Complex assemblydesign support 5

Associative photomaskdefinition 6-7

Finite element analysis(FEA) of MEMS structuresfor thermomechanical,electrostatic, and fluidflow behavior 79

Design Re-Use 10

Ease of use 11

Collaboration tools 11-12

Tightly integratedcomplementaryapplications 13-14

One standard CAD toolto design everything 16

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Designing Molds Quickly, Accurately, and

Cost-Effectively with SolidWorks

SolidWorks Corporation

S U M M A R Y

Success in today's increasingly competitivemold-making industryrequires fast, accurate, and cost-effective molddesign. SolidWorks® OfficePremium software canhelp you meet these competitive challenges.Automated mold design,analysis and validationtools enable you to produce better molds while savingtime and money. WithSolidWorks software, you can meet customerdemand for shorter leadtimes and reduced pricing,and improve your prof-itability at the same time.

D E S I G N I N G M O L D S Q U I C K LY, A C C U R AT E LY, A N D C O S T- E F F E C T I V E LY W I T H S O L I D W O R K S

Using the SolidWorks “ImportDiagnosis” tools, you canidentify and patch openboundaries as well as repairbad faces. The result is a 3Dmodel that is ready fortooling design.

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Requests for Proposals

Most requests for proposals (RFPs) consist of either a 3D solid model or a series of2D drawings that defines the geometry of the injection-molded part. The first stepin responding to an RFP is to assess the customer’s part geometry. SolidWorkssoftware can open more different types of CAD files than any other design system.Whether you receive neutral file formats, such as DXF™, DWG, IGES, STEP, ACIS®,and Parasolid®, or formats that are native to other systems, such as Inventor®,Mechanical Desktop®, Unigraphics®, CADKEY®, AutoCAD®, Pro/ENGINEER®, andSolid Edge®, SolidWorks software allows you to access the geometry.

Because data errors can occur when importing geometry from another design sys-tem, SolidWorks software provides a comprehensive set of tools to fix importedfiles and clean up geometry. You can automatically create a solid model duringimport by simply knitting together entities in a neutral file into solid geometry.SolidWorks software also provides diagnostic tools to help you knit entities into asolid. The “Check Entity” capability, for example, lets you identify and locate geom-etry problems. Using the SolidWorks “Import Diagnosis” tools, you can identify andpatch open boundaries as well as repair bad faces. The result is a 3D model that isready for tooling design.

After you have imported the part geometry, you can use SolidWorks-integratedtools to gather the information you need to estimate the cost of the mold and for-mulate a quote. With MoldflowXpress, you can predict whether you can create anacceptable mold based on the original 3D solid model of an injection-molded plas-tic part. You can even assess moldability based on geometry, injection location,type of material, and processing conditions. This information makes it easy for youto determine the number of gates, as well as the runner and cooling systemsrequired. You can use the SolidWorks undercut detection capabilities to identifyareas of the part that require side action in order to eject the part from the mold.SolidWorks software also includes a “thickness checker,” so you can pinpoint

MoldflowXpress gives designers confidence that parts can be filled in the molding process.

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Streamlining the Design of Packaging Machinery

SolidWorks Corporation

S U M M A R Y

To succeed as a designerof packaging machinerytoday, you must createhighly innovative productsand get them to marketfaster than your competi-tors. SolidWorks® softwareoffers unique capabilitiesthat can help you meet the challenge, enablingyou to explore and testmore design alternatives,improve quality, andstreamline your entiredevelopment process.