01. Engineering Design

01

Engineering Design

AEON offers a complete engineering design service, backed by a fully-assured and proven design process.

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Technical Requirement Specification (TRS)

AEON works with you to establish a clear set of Technical Requirement Specifications. These specifications will provide the foundation to our designed system and will help our engineering team to contextualise and understand your needs in a clear and succinct way. We work with our clients, drafting the specifications together so that everyone understands where we have flexibility, and where we have hard constraints.

 

As part of our specification workshop, we’ll ask questions about the intended performance of your system, operating environments, verification, cost, scheduling and lifecycle constraints (such as maintainability). Our affiliation with the International Council on Systems Engineering (INCOSE), and experience in eliciting requirements for very complex systems means we are thorough, often suggesting new requirements and identifying opportunities to extract additional value and benefit.

CONCEPT DESIGN AND DOWN-SELECTION

AEON generates conceptualised designs, which fulfil the Technical Requirement Specification. At this stage, fulfilment of the requirements is generally demonstrated by hand calculations and simple analytical methods. We clearly identify all of the constituent components of the design, their interfaces and any load paths (as required). We discuss the concept designs with you, identifying the advantages and disadvantages of each concept, how it will be manufactured, assembled, tested and operated. Working with you, we will down-select a singular concept from those generated.

Detail Design and Analytical Verification

The chosen concept design is fully designed using either Siemens NX or SolidWorks Computer Aided Design (CAD), depending on your preferences. The design is analysed using Siemens NX Advanced Simulation (Finite Element Analysis) to assure performance requirements are met, and that margins of safety / safety factors are realised; all our advanced simulation results in an understandable report (written in plain language), providing details of the inputs used, model abstractions, assumptions, the calculated results, and how these affect our design and specifications.

 

At this point it may be necessary to tweak the design to attain the performance specifications; we use this to provide confidence and assurance to our design’s capabilities. Following analysis, the design is formalised into manufacturing drawings. Each component is drawn, dimensioned and toleranced to assure correct manufacture, inspection, assembly and use. Where feasible, components are optimised for manufacture to reduce costs and expedite delivery of the final product.

 

All of our engineers are trained in BS ISO 8888 Geometric Dimensioning and Tolerancing.

The Manufacturing Process

AEON can prototype any design. We have in-house manufacturing capability, but for our larger jobs we utilise our wide network of UK-based manufacturers who are capable of subtractive and additive manufacture of metals, plastics, ceramics and composites. Our vast experience in R&D and aerospace engineering means we’re experts in understanding mechanical and thermal performance requirements so you can be assured that the specification of materials, manufacturing and assembly processes (incl. heat and surface treatments) is second to none.

 

Our clients demand high standards, and equally we demand high standards from our suppliers. We vet and audit manufacturers regularly, ensuring that we remain compliant to quality management systems.

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    Manufacturing Processes

    Milling, Turning, Laser Cutting/Water Jet Cutting, Gear Cutting and Hobbing, Electrical Discharge Machining/Spark Erosion, Broaching, Reaming, Rifling, Electropolishing and Abrasive Polishing. Additive Manufacture – Green Body, Hydrostatic Pressing, Metal/Plastic Printing, Sheet Metal and 3-Axis Tube Bending, ARC, MIG and TIG Welding, Friction Welding, Capacitive Discharge Welding, Submerged Arc Welding.

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    Materials

    Mild and Stainless Steels, Aluminium Alloys 1xxx – 7xxx, Titanium 6Al-4V, Inconel, Invar, AlBuMet, Filled and un-filled Polyetheretherketones (PEEK), Carbon Fibre Composite Systems (Mitsubishi Fibres), Waspalloy, Molybdenum Alloys, and Copper-Beryllium Alloys.

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    Coatings and Treatment

    Galvanising/Zinc Coating, Solid Lubricant Coating (MoS2), Surtec 650V Hexavalent-free Conversion Coating, Alocrom/Alodine 1200, LORD Corporation Aeroglaze Z306 and Z307, Optical Coatings such as Vantablack (VANTA) and Acktar Magic Black. Chemical Vapour Deposition Plating (all varieties), Anodizing/Anodising, Case Hardening, Annealing, Tempering and Quenching, Optical Polishing.

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    Assembly, Integration and Verification (AIV)

    The purpose of AIV is to verify each component has been correctly manufactured, typically this is performed by a technician using a Coordinate Measuring Machine (CMM) or 3D-Scanner. Dimensions outside of the acceptable manufacturing tolerances are either rejected, re-worked or waivered (providing specifications are still adhered to). Components are then assembled and integrated, where necessary using the correct and sometimes specialist tooling. AEON have extensive experience in the assembly of prototype equipment, and any learnings made are fed back to the design team, should there be a need to make refinements or optimisations. AEON has a dedicated assembly and testing facility for such activities, and access to a Class 1000 Clean Room should this be required. Once assembled, AEON has testing a broad range of facilities to verify that the final product adheres to the specifications set out in the TRS.

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