Mark Davies from of Metalmark thanks Syngineering 

Mark Davies, Director at Metalmark, recently approached the team at Syngineering for verification and optimisation of one of his designs. He wanted them to help him achieve a high performance lifting hook with significant cost savings, and Syngineering utilised FEA (Finite Element Analysis) to achieve the best result.

As Mark explains, “We developed the design to a pretty high standard, so it was quite well-advanced. We then approached Syngineering who suggested some options.”

Stronger and lighter

“Syngineering improved the design by using FEA to identify a stress concentration. They then came back to us with a number of options, including one that was far better than our original design.

Stronger and lighter

“Syngineering improved the design by using FEA to identify a stress concentration. They then came back to us with a number of options, including one that was far better than our original design. By making a few small changes to the shape, they were able to eliminate the stress concentration and make the hook stronger and lighter, but just as effective.”

“For the second part of the process, they carried out further analysis to remove even more material and weight from the product, but without compromising the strength. This made it cheaper for us to manufacture on a per-unit basis, as a different manufacturing process would mean the reduced material savings could be realised.”

“Overall, they optimised our original design and saved us money, which is something we couldn’t have done ourselves.”

Skilled, proactive team

“I like that the team at Syngineering have a proactive approach,” says Mark, “which is the reason we keep going back and working with them.”

“Generally when I work with other engineers, I find that they will dictate terms instead of working with me to come up with a solution. Many of them have problems dealing with jobs on a ‘nuts and bolts’ level—but the team at Syngineering are totally different.

Remain competitive“They’ve obviously come from a manufacturing background and been on the tools themselves. They understand the reality and challenges of getting a product to market—and they take the practical steps needed for me to achieve that end goal.”

“In our industry it’s important to remain competitive. The team at Syngineering help optimise our products and make them as low-cost as they possibly can be. I’d recommend their services to others in need of FEA and  product optimisation.”

Browse Syngineering’s photos on Facebook to see more FEA projects that we have worked on.

“Working with Syngineering enables us to outsource certain manufacturing tasks – which decreases overall production costs and helps to grow our profits,” explains Ben Woodgate, Director.

Stronger and lighter

“We sell a range of Land Rover 4×4 accessories and parts in our online store.I’ll build a product prototype, such as underbody protection, steering and suspension, or front and rear protection, and then I’ll take it to the guys at Syngineering.

They use their engineering expertise to provide me with highly accurate, professional engineering drawings, which I then pass on to the companies that we outsource to do the cutting, section curving or ring-rolling.

This makes the manufacturing process much more affordable – and allows us to pass those savings on to our valued customers.”

Stronger and lighter

“We sell a range of Land Rover 4×4 accessories and parts in our online store.I’ll build a product prototype, such as underbody protection, steering and suspension, or front and rear protection, and then I’ll take it to the guys at Syngineering.

They use their engineering expertise to provide me with highly accurate, professional engineering drawings, which I then pass on to the companies that we outsource to do the cutting, section curving or ring-rolling.

This makes the manufacturing process much more affordable – and allows us to pass those savings on to our valued customers.”

Expert engineering input for difficult projects

“In the beginning, working with the Syngineering team was a learning curve because of the complex nature of our 4×4 products,” says Ben.

“But they were happy to get involved and use their experience to come up with suggestions and improvements.”

“They often help make parts stronger and lighter by suggesting alternative thicknesses or different materials for products, as well as helping me redesign products to use less material. In one instance, I was building bull bars that were 8mm thick, and the Syngineering team advised me that they could be redesigned to be just 6mm thick AND stronger. Of course, this was better for our manufacturing costs and better for our customers (since for 4×4 rivers, a light load is important for optimal performance).

I like that Syngineering take the initiative when working on our products. They are open to any challenge, and always try and  find a way to improve my prototypes.”

 When it comes to engineering drawings, accuracy is key

“At APT Fabrications we design, manufacture & sell high quality 4×4 components – so quality workmanship is extremely important to me.

I need my engineering drawings to be consistently professional and accurate so my outsourced suppliers can manufacture high quality parts to my specifications. That’s why I continue to use the team at Syngineering.

I usually deal with Ricky, and we have a good working relationship. He’s easy to communicate with – and I appreciate that he takes the time to come up with practical, workable solutions. I’d recommend them to any other fabrication companies.”

Browse Syngineering’s photos on our Facebook page to see more 4×4 parts, as well as other projects we have been working on.

Our draftsman, tradesmen and engineers can design and/or certify your platforms, walkways, stairways or ladders to comply with AS 1657. Our RPEQ certification will give you peace of mind.

We also over a range of step overs and can customise these to your specification. We certify and stand by everything that we design.

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Using this model, the engineers could then optimise the design changing the design of the trommel wheel spokes.

The design improvements were then checked using the original FEA model.

Click here for more information on Syngineering and FEA

Many problems can be solved by our experienced engineers, however, there are times when the most talented engineers need to use FEA to help solve some of the more complex engineering problems.

The team of experienced engineers have used FEA to identify fatigue stress raisers, optimise designs and verify designs.  Some of the applications include lifting beams, vacuum lifters, transport skids, trommel wheels, lifting dogs, storage racks, pressure vessels, press dies, and many more …..

Click on the Syngineering and FEA link to find out more

Have you ever thought about the how many trestles you have in the workshop?

Have you ever wondered how often you use them?

Are they engineered and certified?

Syngineering can check and RPEQ certify all your trestles for as little as a few hundred dollars each.

“We rely on the huge amount of detail the Syngineering team put into their engineering drawings.”

When Paul Curley, Operations Manager at Virginia Sheet Metal requires engineering drawings to fabricate products for his clients, he turns to Syngineering — because he knows they’ll always provide him with quality work.

“Syngineering not only give us detailed drawings, but also an incredibly quick turnaround — so we can deliver for our clients.”

“Often our clients will give us a baseline of what they want with some rough sketches,” he says. “Or sometimes they will have done the drawings, but want us to certify the product to make sure it can take the load. We give these to Shane, then he certifies them and draws them, and then he passes them back to us for fabrication.”

“We deal with Syngineering a lot, as these types of requests are becoming increasingly popular. We usually speak to Shane and the team about two or three times a week. They always give us what we need to get the job done!”

Fast turnaround times

Paul also likes dealing with Syngineering because they give him a competitive edge by delivering drawings promptly. He says: “From other engineers you might have to wait about three weeks — and there is always the danger that you might lose the job if the waiting period is too long.”

“Syngineering not only give us detailed drawings, but also an incredibly quick turnaround — so we can deliver for our clients. Obviously, when working on a job, we can’t go any further until we get the required plans, so we like the fact that working with Syngineering isn’t a bottleneck.”

Increased safety awareness

“Everything must be done properly these days, as safety is increasingly important. For example, we might have to produce a stand that will take 500kg, and it will have to come with the certification plates,” says Paul. “The guys at Syngineering help with every aspect — even specifying the fillet size needed, as well as giving us any other information required for us to spec out the job.”

Comprehensive engineering drawings

“When dealing with Syngineering, we rely on the huge amount of detail they include in their engineering drawings. This includes a complete parts and components list, so our fabricators know exactly what they need to do the job.

“The guys in the shop love it, as it takes all the heartache out of the process! I’d definitely recommend their engineering services to other fabricators.”

At Syngineering, we’re passionate about providing you with expert design advice and professional engineering drawings. Call us today to discuss your next project.