The patented Accelerated Concept to Product (ACP) Process® has revolutionized and streamlined the product development process, through optimization led design. The performance-driven development process relies heavily on simulations to meet timing and budget targets, whereas the traditional processes have been built around a build-test philosophy.
The key benefits of the ACP Process include the capability to reduce product development costs by 10-15%, product mass by 20-25% and product development time by 30-35%, while improving product performance in terms of stiffness, NVH, crash/safety and durability.
This technique is a proprietary, performance-driven, and holistic product design development method, that is based on design optimization. ACP incorporates the use of multiple CAE tools to generate an optimal design solution. The 3G Optimization is employed and allows engineers to design a concept model utilizing a holistic design approach. It incorporates material types and properties (Grade and Gauge), Geometry (shape), and manufacturing processes for the optimum weight and performance.
Contrary to conventional methods where just one or a few design concepts are evaluated, the ACP process allows for hundreds of design concepts under multiple load conditions. Only the concepts that meet all of the design targets and manufacturing constraints are initiated. The resulting concept(s) are designed, analyzed, and optimized using loading, manufacturing, material, and cost constraints. CAD data is then generated for the most optimal design. Next, our team takes the design to the production level (preparing it for manufacturing) based on the available manufacturing processes, while providing production support.
ETA is the leading full service CAE (Computer Aided Engineering) supplier to the global automotive industry, offering extraordinary capabilities in CAE to support product development. Our team is skilled in using event based simulations of dynamic non-linear systems to analyze a variety of products.
ETA’s unique, Accelerated Concept to Product Process approach has been used on over 36 vehicle programs in the U.S., Europe and Asia. The use of this methodology reduces testing time, helps to shorten the product development cycle, allows for early prediction of road loads, improves durability prediction through dynamic analysis and reduces cost.
Our team has extensive experience in the analysis of durability, NVH (Noise Vibration and Harshness), vehicle dynamics, crash/safety, metal stamping, CAE process development and manufacturing process improvement for a variety of industries.
With over 37 years of experience in the area of CAE, ETA has developed substantial expertise in the following areas:
- Full vehicle, sub-system and component development programs – Management, CAE and design using PreSys and ANSA
- Advanced crash & occupant safety simulations – Concept, development and test/CAE correlation using LSDYNA
- Durability, fatigue and NVH solutions using VPGSuite
- Concept, development and verification (Road load)
- Design optimization using ACP OpDesign
- Metalforming applications using DYNAFORM – Stamping effects, tool design and performance
- Manufacturing process simulation
ETA offers design optimization services for existing product refinement or clean sheet designs to complement internal product development processes. It can provide significant results in terms of mass and cost reduction, while overall product performance is improved. The design optimization process can be applied to any product design from a component, sub-system assembly and full vehicle.
The optimization process analyzes hundreds to thousands of possible designs to find the most efficient design solution. It locates the optimal shape for the design, along with the precise level and placement of the material. Beyond structural performance, the balance of multidisciplinary objectives such as cost, manufacturing constraints and material handling are considered at the onset of the project.
Design Optimization Results
- Reduce Product Development Cost by 35-40%
- Improve Manufacturing Efficiency
- Reduce Product Mass by ~ 40%
- Improve Product Performance
- Improve Fuel Efficiency