In designing a combustion chamber for a small gas turbine, material selection was critical due to temperatures exceeding 1200°C.

Choose a material that can withstand thermal stresses while maintaining structural integrity.

Evaluated thermal conductivity, coefficient of thermal expansion, and creep resistance; compared Inconel 718, TiAl alloys, and ceramic matrix composites using material property databases and finite‑element thermal stress analysis.

Selected Inconel 718, which met the temperature and stress criteria, resulting in a 10% weight reduction and a projected service life increase of 20%.

Tasked with verifying the safety factor of a new gearbox housing under peak torque loads.

Conduct an accurate FEA to predict stress distribution and identify potential failure zones.

Imported the CAD model into ANSYS, cleaned geometry, defined material (AISI 4140 steel), applied realistic boundary conditions and mesh refinement in high‑stress regions, ran a static structural analysis, and performed a mesh convergence study.

The analysis revealed a maximum von Mises stress 15% below the yield limit, confirming the design met safety requirements without additional reinforcement, saving $8,000 in material costs.

Redesigning a complex bracket for an automotive assembly line to reduce production time.

Modify the design to be easier and cheaper to manufacture while maintaining functional performance.

Conducted a DFMA review, reduced the number of machining operations by consolidating features, introduced standardized hole sizes, added draft angles for casting, and selected a material compatible with existing stamping equipment.

Manufacturing time dropped by 25%, tooling costs decreased by $15,000, and the bracket passed all functional tests, leading to a smoother integration into the assembly line.