Case Studies

Read our case studies to learn about our successes in the following industries:

RocketCustomer: Rocketdyne

Challenge

The RS-68 program was challenged to produce a simple engine that would be cost-effective when jettisoned after a single launch. To achieve this, the RS-68 has 80% fewer parts than the multi-launch Space Shuttle Main Engine (SSME).

Products

Delta 4 rocket launch vehicle

Engineering process

The legacy design is converted from Pro/Engineer to CATIA V5 for modification to meet a new customer’s delivery requirements. Accuracy and model quality must be maintained to meet requirements for aerospace manufacturing processes.

Elysium Solution

Elysium DirectTranslators converted assemblies for an entire rocket booster from Pro/Engineer to CATIA V5 with the precision required for manufacturing. Elysium DirectTranslators assure the highest possible fidelity because they employ the application programming interfaces of both Pro/Engineer and CATIA to translate solid model geometry, topology, and assembly relationships.

Results

Rocketdyne delivered the RS-68 for the Delta IV program at a cost of $14 million each, compared to $50 million for the SSME.

EngineCustomer: Renault Sport Formula One Team

Challenge

Meet Renault Motorsport’s high demands of precise accuracy and time constraints

Products

Formula 1 competition engines

Business needs

Formula 1 represents the best of the best in motorsport. Renault Sport F1’s engine partners similarly represent the cream of the crop; Red Bull Racing, World Champions from 2010 to 2013, Renault Sport Formula One Team, champions in 2005 and 2006, and Scuderia Toro Rosso.

To win against teams such as Ferrari or Mercedes, engines must deliver perfection at every race; engine failure is not an option. Maintaining this level of competitiveness requires the engineering team to know every part precisely. New parts must be a perfect fit and collaboration with suppliers unambiguous.

Engineering process

High performance engine parts are purchased from many suppliers with short lead times. Engineers deliver high quality, ready to manufacture CAD models in the format of each component supplier’s CAM software. Data translation must be fast, automated, error-free, and driven by Renault’s ERP process.

Elysium Solution
As each part or assembly is released for production, Renault Sport F1’s ERP system communicates with its PDM system to check the appropriate CAD model and send to Elysium’s PDCubic server for translation to the suppliers’ CAD format using Elysium’s ASFALIS automated translation software. Each model is checked for geometric defects before and after translation. Suppliers use these models to quote prices and delivery dates and to provide feedback about design changes needed for efficient manufacturing. When orders are approved, models are ready to use with numerically controlled milling machines and CMM inspection systems. The PDCubic translation server stores a profile card for each supplier with the target software and release level.

Customer: Leading supplier of connectors and interconnect components

Electronics ClientProducts

Electrical connectors, antennas, switches, and other components

Challenge

Interconnect products play a critical role in Aerospace, Defense and Automotive industries. As devices become smaller and more complex, Engineers must rely on sophisticated CAE analysis and CAM manufacturing solutions to drive packaging configuration and manufacturing quality. CAD interoperability provides a unique path to maintain data integrity no matter what CAD system the customer or supplier utilizes.

Engineering process

Prototype and production tools are secured from a range of tooling suppliers worldwide. Highly accurate CAD models are delivered in the format of each tooling supplier’s CAD software. Software and support costs for data translation must be minimized.

Engineering and tool design process

The customer is standardized on OneSpace Designer as its CAD system for 3D modeling. Products are produced mainly by injection molding. Mold suppliers employ a variety of CAD and CAM systems.  They require data in many CAD formats including SolidWorks, Pro/Engineer, Siemens NX, CATIA, Autodesk Inventor, Parasolid, ACIS, and IGES. Bi-directional communication is necessary because mold makers often request changes to reduce mold complexity, increase finished part quality, and reduce costs.

Elysium Solution

The customer selected Elysium to provide CAD conversion with complete quality checking and automated healing of surface defects. Rather than support a hardware and software environment necessary for a multi-CAD translation system, the customer leveraged Elysium engineering support teams to provide reliable, round-the-clock translation servers for all its facilities. The translation service gives the customer not only converted models, but also reports indicating which models have been translated, problems with source data, corrective action taken, and dates and times when jobs are run.

Results

With 75 years of history and over 100,000 reliable products, the customer has maintained a global leadership including everything from electronic, electrical and fiber optic interconnects to switches and application tooling. Elysium was able to deliver accurate data translation as well as assurance to the customer that every step in the data translation process was fully managed.