Simpler Designs Outperform Complex Ones
In the world of advanced material fabrication, the allure of complex designs often drives engineers to overengineer products. While the intent behind these intricate designs is usually to maximize performance or address potential use-case scenarios, the reality is that overengineering can introduce significant challenges, particularly when working with thermoset composite laminates.
At Atlas Fibre, we’ve seen firsthand how simpler, well-optimized designs not only streamline production but also outperform their complex counterparts in durability, efficiency, and cost-effectiveness. Let’s explore the key pitfalls of overengineering and how focusing on simplicity can yield superior results.
Increased Production Costs
Overengineering often translates to unnecessary design complexity, which directly impacts material usage and extends production times. Complex geometries may require additional machining, prolonged curing cycles, and higher labor inputs—all of which drive up costs without proportionate returns in performance.
By simplifying designs, manufacturers can leverage the inherent strength and versatility of thermoset composite laminates without inflating production expenses. Atlas Fibre’s vertically integrated supply chain allows for streamlined, efficient manufacturing, ensuring that designs stay practical and cost-effective from concept to completion.
Excessive Void Formation
One common issue in overengineered composite designs is increased void formation during the manufacturing process. When designs are unnecessarily intricate, there is a higher likelihood of air entrapment, leading to voids that compromise the structural integrity of the final product.
Simplified, more uniform designs facilitate better resin flow and consolidation, reducing void formation and enhancing the overall strength and longevity of the composite. Our fabrication expertise helps clients identify design redundancies that can lead to such defects, ensuring optimized, high-integrity laminates.
Resin-Rich Areas
Overcomplicated designs often result in regions with excessive resin content. While resin is vital to composite strength, disproportionate amounts can lead to brittleness and reduced mechanical performance.
Atlas Fibre’s engineering team emphasizes design optimization to maintain a balanced resin-to-fiber ratio, ensuring consistent performance across all areas of a component. This precision helps mitigate the risks associated with resin pooling, preserving the composite’s integrity.
Longer Cycle Times
The more intricate a design, the longer the production cycle. Complex designs can demand extended curing and cooling times, negatively affecting production efficiency and increasing energy consumption.
By simplifying part geometries, we help our clients achieve faster turnaround times without sacrificing performance. Our advanced machining capabilities and expertise in thermoset composites allow for rapid, precise fabrication that meets even the most demanding timelines.
Equipment Limitations
Overengineered designs may necessitate specialized, costly equipment that many manufacturers either do not have or find impractical to operate. This leads to limited production scalability and increased overhead costs.
Atlas Fibre’s diverse equipment lineup, including state-of-the-art CNC machines and dedicated cleanroom facilities, enables us to fabricate a wide range of complex and simple components. However, we always advise clients to evaluate whether intricate design features are essential or if a more straightforward approach can achieve the same performance goals.
Reduced Recyclability
Highly engineered thermoset composites are often more challenging to recycle or repurpose due to the complexity of their design and material composition. This can raise sustainability concerns and limit end-of-life options for components.
Simpler designs allow for easier material separation and recovery, contributing to more sustainable manufacturing practices. Atlas Fibre’s focus on designing for recyclability ensures that our clients’ products align with evolving environmental standards.
Potential for Manufacturing Defects
Overengineering increases the likelihood of manufacturing defects such as fiber misalignment, foreign inclusions, and inconsistencies in material properties. Each added layer of complexity introduces another potential point of failure.
By prioritizing clean, streamlined designs, Atlas Fibre reduces the chances of defects and enhances overall product reliability. Our rigorous quality control processes ensure that even the most complex parts meet stringent performance requirements.
Difficulty in Quality Control
Maintaining consistent quality across production batches is more challenging with intricate designs. The more complex the part, the harder it becomes to ensure uniform performance, leading to potential variations in product efficacy.
Atlas Fibre’s vertically integrated approach and advanced metrology equipment allow us to deliver precise, repeatable results for all components—ensuring that quality remains consistent, even as production scales.
Embrace Simplicity for Better Performance
In thermoset composite fabrication, simplicity isn’t just a cost-cutting measure—it’s a performance enhancer. By avoiding the pitfalls of overengineering, manufacturers can produce composites that are stronger, more reliable, and easier to fabricate.
At Atlas Fibre, we work closely with clients to refine their designs, ensuring that simplicity and efficiency drive every project forward. Our expertise in machining thermoset composites allows us to turn streamlined designs into high-performance components that meet and exceed industry demands.
If you’re looking to simplify your designs and improve production outcomes, let’s start a conversation. Together, we can unlock the full potential of your thermoset composite projects.