SERVICE:  Finite element analysis (FEA) and structural problem solving

CLIENT: Ohio Steel

A crucial step in plastic part design and engineering is performing Finite Element Analysis (or FEA). Ohio Steel wanted to load 750 pounds of dirt into the molded plastic trailer we designed for them. The cart needed to be structurally sound and not buckle or flex more than .125” under the load.

To contain the forces of the load and maintain the integrity of the plastic cart body, we focused on the hoop strength of the design. The pattern of the ribs on the bottom of the cart was also key to supporting the desired load and we made several changes to the height and thickness of these ribs during development. Using ANSYS® Finite Element Analysis software, we subjected our 3D model to a 1000 pound load (a 25% safety factor) which yielded a mere .039” flex around the top perimeter of the cart body. Without the FEA testing, the parts could have been over-engineered, resulting in wasted plastic and increased part cost that would have jeopardized the success of the cart at retail.

Plastics material selection is also a very important part of an FEA. Materials with the desired aesthetic attributes were tested virtually for their performance under load, thus saving our client costly production mistakes.

Our Finite Element Analysis models passed the retailer’s field-testing specifications and gave Ohio Steel the confidence to proceed to production.

>> See the cart we designed for Ohio Steel.