Engineering Services
Our idea of engineering solutions is to offer world-class solutions to clients with a total understanding of all needs, requirements, challenges and pain points. In a constantly shifting technological playground, we help companies gain the competitive edge with our transparent practices and successful delivery.
With steely resolve, best in class practices and proven execution models, we are up to the most hardened of challenges. When there is a paradigm shift in expectations across verticals and horizontals and mounting customer and business pressure for innovation, Prodenc’s engineering solutions and support services are powerful tools to bank on. With a view to provide globally compliant solutions, bring a comprehensive and integrated approach to innovation, within the regulatory framework.
Besides our service in medical and consumer domain, we cater services in following areas to other domains as well.
Concept design
Prodenc brings unmatched ability to convert your basic ideas and user needs into workable concepts and prototypes. With cross functional teams and highly competent engineers with experience in a variety of niches including, industrial design, product development, material science, manufacturing, and engineering, we can deliver concept designs, feasibility studies and more!
Prototyping
Any product needs to be tried, tested, and perfected to ensure a smooth launch and rapid consumer acceptance. To this end, we undertake functional prototype development for companies. Whether it is for evaluating new concept or design changes or improvisations based on innovations, for functional testing or feasibility study, we develop functional prototype using a variety of prototyping techniques.
Material selection
Products work best when they are engineered to precision and manufactured using the most suitable of materials, which is again a balance of cost, performance, and intent. Our material science experts specializing in polymer science bring in-depth know how in material selection.Be it cost savings or product improvement: we are ever open to sharing our expertise and knowledge.
Detail Design and Engineering
Research, analysis, feasibility studies and so on culminate in ultimately in design detail and engineering, to develop the best product. Our collaborative teams deliver bespoken solutions that are high in value and perfect in function. Prodenc undertakes tasks based engineering projects, or even complete ownership, in executing designs and developing the product from the concept to finish.
CAE (Computer Aided Engineering)
Mold flow analysis
Filing analysis– Flow analysis is the first stage of the molding simulation process. Flow calculates the melt front advancement that grows through the part from the injection location, and continues until the switch-over point to packing. Our flow analysis solutions provide the ability to simulate, identify, and optimize the process to avoid molding uncertainty or resolve an existing injection molding problem.
Filing analysisFlow analysis is the first stage of the molding simulation process. Flow calculates the melt front advancement that grows through the part from the injection location, and continues until the switch-over point to packing. Our flow analysis solutions provide the ability to simulate, identify, and optimize the process to avoid molding uncertainty or resolve an existing injection molding problem.
Packing analysis Filling analysis is only the first stage in a series of cost saving analyses related to the molding. Packing analysis builds on the results of the filling analysis by extending the first stage of the injection molding process into the packing phase. This second stage fills the non-filled portion of the mold with additional material to compensate for the loss in volume as the material shrinks. The part is then held under pressure while it solidifies.
Cooling analysis Cooling analysis provides the ability to accurately simulate any number of cooling designs to achieve uniform part cooling, minimize cycle times, and reduce warping due to non-uniform cooling.
Warping analysis Warping analysis provides the ability to optimize part design, material selection, mold design and processing parameters to manage and reduce warping of parts, in order achieve the intended part design.
Shrinkage analysis - Predict and control post-molding shrinkage and evaluate the structural integrity of the molded part.
FEA (Finite element analysis)We use finite elemental analysis (FEA) as a mathematical tool to solve complex problems, which are either impractical or time consuming to solve. Performing a FEA at early stages of design cycle saves a lot of time and money by quickly narrowing down candidate designs.
Many a time, while designs seem good on paper they may not exactly deliver when the actual prototype or model is created, due to a host of factors. These may either due a single contributing factor or a combination of factors and conditions.
This process of elimination of such designs can be made robust by combining FEA with a DOE (design of experiments) and Robustness analysis (through Monte Carlo simulations).Even without performing a full validation on FEA models, they can still be very useful in performing comparison studies (design A vs design B, etc.). Using FEA results, not only design but appropriate materials can also be selected while targeting intended design functionality is achieved. There are 3 critical processes associated with the above.
Model verification
Choosing and creating the right mathematical model is the first step of any Finite element analysis (FEA) practice. A model that is free of numerical artifacts and noise is critical in order to obtain an accurate solution. Model verification ensures this through the adoption of best modeling practices.
Model calibration
This is the step that connects FEA results to experimental results. Model parameters are adjusted if needed so that the model results align with the experimental results. This is not a validation yet, for which the next step needs to be followed.
Model validation
This step ensures the predictive capability of an FEA model. After successful model verification and calibration, the model is tested for a separate set of input parameters and results checked with experimental results. Any big variations with experimental results suggest that verification and calibration steps need to be re-run with higher resolution and assumptions need to be revisited. Only a successfully validated model can be become a predictable model.
CAD Modeling/Drafting
Prodenc has a variety of CAD tools to provide end to end modeling and drafting services. Using the latest versions of Solidworks, PTC Creo, Catia, NX and AutoCAD, we create robust and parametric CAD models and drawings for the parts and assemblies. Our designers are experienced in plastic, sheet metal, die casting, and machined parts design. CAD models are made based on the design needs, manufacturability and other relevant practical factors.
Manufacturing Solutions
We have solutions for your every manufacturing need. We are specialized in injection mold design, Press tool design, Die casting design, CAM programming, Electrode planning for mold cavities, tool manufacturing, machining parts, and tool validation and qualification.