Tag Archives: Cad

A manufacturers guide to… 3D CAD

Thirty years ago, when I first started using CAD software, it was no more than a means of creating an accurate 2D drawing.

Fast-forward three decades and the thought of designing something on paper is now – for the vast majority of manufacturers – a completely alien concept.

The introduction of 3D CAD software into the manufacturing mix has made businesses the world-over far more creative while vastly improving product quality.

Central to its success has been the rise of the internet and increased connectivity. I mean, can you imagine sending a drawing overseas and having amends fed back via return to sender?

While the manufacturers of yester-year may have had more localised customer bases, today’s manufacturing landscape couldn’t be any more contrasting, especially here in the North East.

As one of the UK’s most successful exporting regions, today’s manufacturers rely heavily on being connected to the rest of the world – be it dealing with suppliers or communicating with customers – and the increasing adoption of 3D CAD has been central to this success.

By reducing – and in some cases, completely removing – the need for complex programming, meetings and time delays caused by logistics and travel, the implementation of CAD has allowed parts to be manufactured and sold worldwide without worldwide travel, making the engineering and manufacturing environment way more collaborative.

Among the first industries to realise the benefits of CAD were the automotive and aerospace sectors. They were the early adopters as they had the money to invest in the technology and, in many cases, were used as guinea pigs to showcase the software and its benefits.

They swiftly learned that using 3D CAD not only reduced design and development time, but that it also highlighted errors at the early phases of a project. Errors during manufacture can be incredibly costly, particularly in high price, highly complex, high-volume products, so the automotive and aerospace companies bore witness to the immense benefits almost immediately.

Small workshops and manufacturers on the other hand were among the slowest to adopt the technology, as the majority of their machines were manual and they still relied on 2D drawings, however the vast majority are now seeing the bigger picture.

In the two years I’ve been with the SAM Project, I’ve worked on dozens of projects from the development of smart rings to large air sterilisers, outdoor garden buildings and material handling solutions, and have seen first-hand just how accessible and vital this technology has become to small and medium sized businesses.

All the projects have had one thing in common… they have given the clients an early insight into their product. The problems which they may encounter and how to overcome them, the manufacturability and complexity of an assembly and how to simplify or use alternative methods. It has helped both de-risk projects and give manufacturers the confidence and drive to further develop their ideas. 

Fifteen years ago, drawing office managers would have laughed at the prospect of a paperless drawing office, just as small manufacturers five years later would have laughed at the thought of their businesses being able to afford such technology.

However, as technology has evolved and the cost of implementing 3D CAD has fallen, it’s now almost impossible to think of any manufacturing business not embracing and reaping the benefits of it.

Looking to the future, 3D CAD will be essential for future product development and manufacture as it is the foundation of an idea. As we move into a ‘virtual world’, a virtual prototype will be required to see virtual reality become reality. Fit, form and function will always have a bearing on a design and although some of this may become automated, creativity, corporate identity and uniqueness will always be important to a company and 3D CAD will only help enhance such traits.

So, if you’re a North East business thinking of learning more about 3D CAD and its many benefits, why not speak to our team of manufacturing experts? We’d be more than happy to talk you through the many options available to your business and how they could drive product and process improvement for your teams.

  • Ian Barrett, CAD and Engineering Specialist at The SAM Project.
For almost 140 years, The Expanded Metal Company has driven product innovation in its sector, producing metal mesh products for construction materials, filters, grilles, walkways and visually striking architectural meshes. The Expanded Metal Company was founded by the patentee of expanded metal, John French Goulding and has been operating on the same site since in 1889. Refusing to rest on its laurels, the company tapped into SAM expertise to help ensure the smooth introduction of a new product line. The company was developing a modular cages range and accessed support from the team of University of Sunderland-based experts to help ensure smooth production processes and iron out some minor design challenges.

Future focus at metal mesh marvels

The opportunity of working with SAM specialists was music to the ears of a firm of Hartlepool metal experts.

For almost 140 years, The Expanded Metal Company has driven product innovation in its sector, producing metal mesh products for construction materials, filters, grilles, walkways and visually striking architectural meshes.

The Expanded Metal Company was founded by the patentee of expanded metal, John French Goulding and has been operating on the same site since in 1889. Refusing to rest on its laurels, the company tapped into SAM expertise to help ensure the smooth introduction of a new product line.

The company was developing a modular cages range and accessed support from the team of University of Sunderland-based experts to help ensure smooth production processes and iron out some minor design challenges.

Managing Director, Phil Astley, said: “The main benefit of the SAM team is that it allows companies like ours to quickly access the exact expertise and guidance required when embarking on a new project.

“I was very impressed with their support and having first met with Roger O’Brien, we met his team at the University of Sunderland and before long we were working closely with them on the redesign of our security cage.”

The company has developed a “flat pack” security cage, a modular system that can be tailored to meet the exacting requirements of clients, which is shipped in a relatively small consignment and assembled on-site.

Kalem Ainsley, Technical Manager and Ryan Pinder, Operations Manager and Head of Continuous Improvement at The Expanded Metal Company worked with SAM’s automation and robotics expert, Neil Taylor, and CAD design expert, Ian Barrett, to hone design specifications and create clear, smooth production processes ahead of the product’s launch at the end of last year.

“By being able to transport the cage packed flat on a pallet we’re being more efficient and reducing our own carbon footprint, as we’re not transporting empty space,” added Phil.

“Alongside the development of our website, which allows customers to configure the cages to meet their own unique needs, this new solution is perfect for a wealth of sectors, as customers can select their own dimensions, colours, whether the cages need wheels…anything they require really.”

Employing 86 people, the Expanded Metal Company has also developed a range of innovative fencing systems and security solutions and serves sectors including construction, filtration, automotive, aerospace, architecture, manufacturing and engineering, agriculture, acoustics and security.

Ian Barrett, CAD and CAM specialist at the SAM Project, said: “The Expanded Metal Company may have been around for almost a century and a half, but it remains laser-focused on setting the pace in the future.

“It was a fantastic experience working with a business that boasts so much knowledge of its sector but remains open and enthusiastic about adopting new technology and processes.”

SAM Innovation and Growth

SAM Features in The Journal

The SAM Project featured in The Journal, published in Newcastle in a special feature in March 2022.

The article covers all of the areas of expertise offered by the the project with an introduction to the Technical Team, alongside case-studies featuring companies who have received support.  There is also information about the grant funding the project offers.

The full supplement can be downloaded here.

Meet our CAD/ CAM specialist

Ian Barrett, CAD and Engineering Specialist, tells us more about his role and how the SAM Project can help SMEs embrace CAD and CAM technologies.

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) technologies were developed in the ‘80s and are now widespread across the industry, helping improve practicality and productivity for businesses the world-over.

Throughout my career, all of my roles have involved some form of design, especially during the early days of CAD adoption, from developing consumer products to large scale heavy engineering projects. I also have a vast knowledge of prototype manufacture (both rapid prototyping and small batch production) and testing.

This has helped me establish an excellent working relationship with customers and colleagues who – as a result – trust my judgement when it comes to all things CAD and engineering.  A business’ needs must be managed, and I take responsibility to gather the relevant information, design or fit a solution to overcome any issues, put them in place and ensure the manufacturer is satisfied and that – more importantly – the problem has been solved, and not just with a ‘sticking plaster’, so to speak.

Due to my experience, knowledge and role, I am actively involved in a whole host of engineering projects, carrying out design layout, concept and prototype design, design for manufacture studies, drawing creation, FEA studies and providing additional information to customers who may require support that is over and above the usual role of a design engineer.

The SAM Project, our Prototype Factory, at The Industry Centre, and most importantly, our staff, allow the region’s manufacturers to experience and benefit from technology and knowledge that – in usual circumstances – would be difficult to access. Especially for small businesses. It’s also all under one roof and on their doorstep, at absolutely no cost to their business.

Recent success stories include using CAD to help an SME manufacturer develop a transparent, bullet-proof security barrier for the armed forces. Not only did we design the modular framework and supporting accessories, we also provided a scale prototype allowing the customer to have meaningful conversations with not just the MOD but also their finance and funding bodies.

Another saw us work with a family-owned beauty salon which – prior to tapping into our support – had absolutely no manufacturing or design experience. We helped them develop their idea for an easy-to-clean, portable, mobile hygiene screen and brought the idea to life by creating a fully functioning prototype. They are now looking at selling the product across the globe.

So, if you’re an SME manufacturer in the North East wondering how you could benefit from adopting CAD, need to provide CAD data and are not sure the best route to do it, or get the most out of your current CAD installations, why not pay us a visit at the University of Sunderland and see for yourself how our support could benefit your business?