A selection of case studies and comments can be found here, from:
- Tecumseh—manufacturer of refrigeration units
- Victrex Polymer Solution—producer of high performance polymers
- Honeywell Aerospace—aerospace enterprise
- Continuum Blue—technology development consultancy
- FORCE Technology—technology consultancy
- Chip Ganassi Racing Teams—auto racing group
- NCS Lab—research services organization
- CETEM—technological center
- Fortune Brands Home & Healthcare—consumer brands company
- PROMES—research center (part of CNRS)
- Novo Nordisk—healthcare company
- Foster & Partners—architectural practice
- Dow—chemicals company
- Finding an alternative for a metal alloy automotive part—typical industrial application
- Cost-effective lightweighting routes for an automotive door panel—typical industrial application
Tecumseh has been committed to innovation and product quality for the air conditioning and refrigeration market for more than 75 years. In an increasingly competitive global market, they wanted to ensure that their material selection processes were rigorous and reproducible, and use these processes to produce high quality products at an optimal price, whilst also considering environmental factors. Tecumseh adopted CES Selector, taking advantage of extensive materials property data, advanced graphical analysis, and specialist tools to support materials selection and substitution decisions. This has ensured that their materials experts can make the best use of their materials understanding and share it within the group. Graphical selection methods helped Tecumseh save 2 million euros. You can now read how just a few weeks' work using CES Selector has led to three-fold reduction in production time for one component, a venitilation unit (pictured), and helped to generate millions of euros of cost savings from making the right materials decisions.
Victrex Polymer Solutions uses CES Selector to demonstrate the benefits of its new materials in applications such as aerospace. They have made use of performance indices to compare new thermoplastic composites with existing materials like aluminum. Material property data is also readily available for export to Excel, and to finite element analysis for component modeling, e.g., to show weight reduction without loss of performance.
During a live webinar broadcast in April 2014, Dr Alan Wood, Principal Scientist at Victrex Polymer Solutions, said CES Selector "allows us to develop these concepts and gives us really good tools for actually going out and selling materials.”
At a webinar in which leading aerospace organizations discussed their use of Granta software, John Perek, Principal Materials Engineer at Honeywell Aerospace, discussed two examples of the use of CES Selector. The first is a materials substitution issue for a pressure regulator housing, where CES Selector was used to help identify an alternate injection moldable material to counter problems with delayed cracking after molding; the PEEK plastic chosen is working well in production. In the second example, CES Selector was used to explore the replacement of an aluminum ATS oil cover with a polymer composite material, providing substantial cost reductions.
Both case studies demonstrate the benefits Honeywell have seen in terms of reduced selection time and cost avoidance. As Perek explained, these benefits come from applying a rational material selection process that is exhaustive, auditable, and repeatable:“that is the process we should all strive for and CES Selector is the tool that helps us achieve that.”
At a webinar hosted by Granta, Dr Mark Yeoman, of UK-based technology development consultancy Continuum Blue, spoke about minimizing risk when selecting or changing materials. He presented a case study showing how his company had used CES Selector to help a client to find a suitable plastic for a container for a new organic solvent range. He explained how it took just a few hours to identify candidate materials, reducing consultancy time from months to weeks, and thus considerably cutting the cost to the client.
The case study demonstrated that the chosen material matched the client’s established production process and also resulted in cost savings. As Dr Yeoman explained:“In under two hours you can find an alternative solution that helps with material costs and reduces the carbon footprint.”
At a webinar hosted by Granta, Benjamin Hornblow, of Denmark-based technology consultancy FORCE Technology, spoke about the challenge of developing products using composite materials: how to determine which materials to use and how to combine them in order to maximize the unique properties and benefits of each. He explained that by using CES Selector, the team at FORCE Technology was able to quickly identify candidate materials for a longboard and evaluate the ways in which they could be combined to achieve optimal results.
The case study showed that the final composite provided a longboard with a smoother ride and 30% weight saving compared to the current state-of-the-art board. As Mr Hornblow explained:“It was great to use the multilayer Synthesizer Tool in CES Selector to ‘test out’ different materials, concepts and configurations early in the design process. This saved valuable time in the more labor-intensive CAD modeling and prototyping stages of the project.”
The engineering departments across all of Chip Ganassi Racing Teams' racing disciplines, inlcuding US IndyCar and NASCAR, are using CES Selector to compare and choose alternate materials to develop stronger, lighter, and more durable race-winning cars.
John Probst, Technical Director, Chip Ganassi Racing Teams, said: “Chip Ganassi Racing is looking forward to utilizing the CES Selector software to make more intelligent material selection decisions. The extensive database offered by the software allows us to compare and select suitable materials and manufacturing processes for all applications of the vehicle. As a racing team, our main goal is to win races and with a product like CES Selector we’re putting ourselves in the best possible position to make that goal a reality.”
NCS Lab is an Italian research services organization committed to supporting research and development. In a case study looking at replacing metal with plastic in medical forceps, NCS Labs concluded "CES Selector allows the systematic selection of the material by using a method based on objective data, mathematical equations (performance indices) and an extensive database. This is essential to prevent numerous computational attempts with many different materials, minimizing the production of prototypes and the number of experimental tests: for this reason, it is estimated a time and money saving of 50%, or greater, in the prototyping and testing steps of the project. Moreover, the effective optimization of the material selection provides real innovation with regard to the project objectives and therefore brings enhanced performance, durability and visibility to the device, thus inducing further money savings during the item lifetime. "
CETEM, a technological center working in the furniture and wood industry in Spain, uses both CES Selector and the Eco Audit Tool. In this case study, they describe CES Selector as "an important technical support tool" and report "time savings of 25 to 40%, depending on each case. Every day we are increasing the number of activities that we realize using this tool".
In terms of sustainability, they emphasize how "the use of the Eco Audit Tool for analyzing the environmental impact of different products is making our daily work easier."
Internationally-renowned architectural practice Foster & Partners use Granta's software to aid materials selection:
"In our industry we are too used to selecting from only a very limited palette of materials. CES Selector is allowing us to ask 'what if?' questions upfront in a comprehensive manner. Access to data is one thing; analytical tools for filtering that data are another: CES Selector is a potent mix of the two that can only increase the likelihood of us being able to innovate."
Dr Salmaan Craig, Foster & Partners
"PROMES Labo (SHPE team) has worked with CES Selector in several areas, including the development of new materials from recycled industrial waste. It has helped save time by allowing us to easily compare traditional materials, select the best available material for specific applications, and clearly identify 'gaps' in material property space where new materials could advantageously be developed. The graphical charts have been particularly useful for clarifying publications and sharing our research."
Anais Jeanjean, Doctorante Vilmor EnR, PROMES
Dr Rüya Eskimergen Nielsen from Novo Nordisk—the leading healthcare provider and developers of medical devices for treating diabetes, haemostasis management, growth hormone therapy, and hormone replacement therapy—provided insights into the benefits of rational materials selection using CES Selector during her presentation as guest speaker at Granta's recent 'Materials Information Technology in Industry' seminar in Denmark
Moen Incorporated, part of Fortune Brands Home & Hardware, has embedded Granta’s software in its product design approach. New or redesigned products and components are examined to evaluate material and manufacturing alternatives.
Dr Tim O'Brien, Vice President for Technical Innovation at Fortune Brands Home & Hardware described the use of Granta software at a seminar in Milwaukee, WI. The report from this presentation explains: "Whenever [Dr O'Brien] approaches a materials problem, he always has a few materials options in mind, but CES Selector usually suggests additional options. Past applications have included a component redesign that cut production costs in half and doubled performance on an important product line."
"We use the graphical capability of Granta’s system and the Performance Index methodology to prove, in a quantifiable fashion, the benefits of polymers over traditional material choices."
Ludo Aerts, Dow Benelux N.V
Granta examined a typical case study of a manufacturer seeking alternative materials for a metal alloy automotive transmission cross-beam. We studied the suitablility of all metals, alloys, compostites and polymers to identify lighter, cheaper alternatives.
In this case study, Granta has investigated the impact of material choice on part cost for lightweighting an automotive exterior door panel. Inspired by the plastic panels in the Smart ForTwo car, we studied the suitability of this class of material as a replacement for steel.