Wayne White

Before joining TriMech in 2012, Wayne worked in companies large and small, and in industries including automotive and battery technology. This path led him to TriMech, where he began as a general application engineer supporting clients working with SOLIDWORKS desktop products. Today, he supports clients in their move to the cloud and, through training and support, ensures they take full advantage of the power of the 3DX platform.

How did you make the shift to focusing on 3DEXPERIENCE within TriMech’s collection of products and services?

I have worked for Matt Kokoski throughout my career with TriMech. Beginning about 2017, he started to ask me for help supporting 3DX because it was new at the time and he was a team of one. I was already watching the trend of everything moving to the cloud and wanted to be part of that, so eventually I asked Matt if I could work on 3DX full time.

I have used cloud-based products personally for more than 15 years and I knew the benefits related to data management and backup, and just connecting large amounts of information and making it more usable.

Plus, I liked the idea of marrying CAD with the cloud.

It can be challenging to be on the leading edge of change, since people are naturally resistant. How do you deal with this?

Some people are still resistant to moving to the cloud. That’s not unique to engineering or manufacturing – there’s a societal shift in how we’re using software.

Our most successful 3DEXPERIENCE clients are those who are willing to put some time into making a few simple changes and trying new things. You have to say, “ok, this workflow doesn’t work the same way anymore, I’m open to adapting.”

People like what they’re used to. You build a history of knowledge and skills and we’re presenting you with a different technology and asking you to retool your brain. The first hurdle is encouraging people to make a change, and we do that through education.

Do clients have misconceptions about what it means to use 3DX?

One misconception is that the cloud is not as secure as storing your data at your physical location behind a locked door. We provide clients with all the information they need about Dassault Systèmes’ ISO-certified management systems and risk management practices to protect their data and privacy.

Speaking of education, how do you support client learning?

There are several options. To start, the MySOLIDWORKS platform has excellent on-demand video content that you can watch when it suits you.

And within The TriMech Group, we have training options that are live and interactive. This gives clients a chance to ask very specific questions, which they always do.

I always recommend TriMech 3DEXPERIENCE training because this is how you will truly understand what the platform is capable of. This is how you learn to make informed decisions about how you want to use the environment to suit your specific needs. Training exposes you to features and benefits of the platform that you’re not likely to tap into otherwise.

It makes sense to invest in the best possible use of the system where all your critical data and communication is stored.

Beyond training, we’re always here to answer questions by phone or by email.

Is there an ideal client for 3DX?

Honestly, 3DX can suit the full range of clients. I will say that small- and medium-sized businesses that don’t currently have a data management solution in place are often the most ready to run with it.

Having said that, very large companies have successfully migrated their existing data into 3DEXPERIENCE; it just takes a bit of time to make the transition.

What are the most attractive features of 3DEXPERIENCE that are making clients move to 3DX as a data management solution?

The first thing I would say is that it’s data management out of the box. The second thing is that 3DX offers rules-based standardization among all users, keeping consistency across the board. 3DX is the problem-solver that leads to efficient data management and effective team collaboration.

For 25 years, people got used to managing their own data. The problem of course is that people leave organizations and trying to pick up where that person left off is a daunting task. Nobody can afford to have errors and delays because of inconsistent data management practices.

3DEXPERIENCE Platform

Why should people choose 3DEXPERIENCE training offered by TriMech Group?

Our training courses are home grown and continually evolving, and we bring all of our years of experience using and supporting 3DEXPERIENCE.

We’ve worked with many different types of clients and know what works best in uploading files, setting workflows and revision schemes, rules that are critical to success, etc.

In our six-hour course, for example, we outline everything the client has to look out for in order to make informed decisions about what will work in their organization. We show them the steps, and all the variables that come into play along the way.

It’s really important to consider the needs of existing SOLIDWORKS users vs. non-users, and we cater to both.

Is the 3DEXPERIENCE training content flexible enough to evolve over time?

We’re always making changes. There are common technical questions that most clients have, and we always answer those; at the same time, we definitely reconfigure the training based on interactions with clients and training participants.

Being cloud-based, 3DX itself changes more frequently that SOLIDWORKS desktop users would be used to. Adjusting the training based on platform updates is critical. I actually had a call yesterday from a client interested in taking the training for a second time.

We can add new modules or courses as new 3DX elements are introduced or as we learn more about what a certain group of clients needs. Right now, I’m working on content for more role-specific training courses.

What makes a successful learning environment for a trainee?

People should come ready to participate. I encourage a comfortable learning space by telling everyone that I also started at zero with 3DEXPERIENCE, and that all questions are welcome. Even when we’re learning together online, you can easily communicate with the instructor. I want people to ask the questions that make their learning valuable.

Businesses who invest in training and development for their people clearly demonstrate that the organization is committed to the platform and this leads to greater success overall.

Why does your team stand out?

I’m proud of the TriMech 3DEXPERIENCE training team because I feel we are among the most advanced. We can answer the basic questions about how 3DX works and we’re also well past that. We’re on top of the evolution of the platform in a proactive way. Combine that with our experience up to this point, and we can quickly solve issues that clients run into.

3DX is a massive platform with far-reaching applications and our client base is diverse. The exciting part is watching clients push the boundaries of its capabilities. Imagine an organization with more than 100 users across many different departments.

We can support any client, small or large, anywhere in the world. For me, this is special and different from my first 10 years in the business. It’s cool that I’m on calls with people in Europe, India, and China.

Are you interested in TriMech 3DEXPERIENCE Training or Support?

Learn more about the 3DEXPERIENCE training courses available and the 3DEXPERIENCE support options for TriMech clients »

Alfred was born out of research into developing robots that can manipulate deformable materials, which change their shape when you interact with them (think guacamole or ice cream). Using a variety of utensils, such as scoops, ladles, and tongs, Alfred handily puts together meals based on the programmed instructions of the kitchen staff.

Why do we need a robot sous chef?

Dexai’s mission is to protect the food service industry from difficult labour shortages and help insulate it from economic ups and downs. At the same time, Alfred can reduce the risk of food-borne illnesses. Everything that Dexai designs meets the standards of the public health and safety organization NSF and each mechanical part in the complex design must be built with safe food handling and safe working conditions in mind.

Controlling Alfred the Robot Sous Chef

Supporting a startup

Dexai CEO David Johnson explained that when he and Anthony Tayoun started the company, they worked out of Greentown Labs in Somerville, Massachusetts. The incubator space has a great relationship with TriMech, which provides and supports software tools that are used across every stage of product development.

“TriMech answered all of our questions,” David said. “How do we get SOLIDWORKS licenses? How do we get a data management solution? TriMech has been with us from the very beginning.”

That beginning was four years ago; as Dexai took the challenging steps of turning an idea into a product, adding to its team, and scaling up production, Hardware Team Lead Justin Rooney said that TriMech became a trusted – and responsive – partner.

“There’s a big human component that I really appreciate about TriMech. It’s very easy to get on the phone with them or email them and get an answer. Even as we were researching 3DEXPERIENCE and comparing it with other products on the market, they seemed to have unlimited time to go through the decision-making process, which was amazing. And later, TriMech allowed me, as an individual with no IT experience, to roll out a PLM product to a big team.”

— Rana Odabas, Mechanical Engineer, Dexai Robotics

“When we were vetting a few different PLM options, TriMech stuck out to me as very available. They offered their services countless times to go through the functionality of 3DEXPERIENCE Works. Understanding that TriMech was always going to be there to answer questions veered us toward choosing 3DEXPERIENCE.”

One shared platform

3DEXPERIENCE Works PDM by Dassault Systèmes is a cloud-based platform that connects engineering and business activity in one real-time, collaborative environment.

Dexai design with 3DEXPERIENCE Works

Rana gave one example of how using the 3DX platform has improved productivity, when each designer is working on different parts, yet they all have access to the digital twin of the product.

“If we have multiple people working on the robot head, they can design their parts in parallel while tracking dependencies in the context of the same assembly. All team members have access to the full assembly and visibility into the latest stage of development. I think this has been the biggest benefit of having 3DEXPERIENCE. It really motivates collaboration across the team.”

In Dexai’s early years, the small team of 10 worked on their own local devices and passed zipped CAD files back and forth, a process not conducive to understanding how one subsystem fits with the rest of the system. Today, with a team of more than 25, they are all connected to the same cohesive platform.

Rana said the productivity of the team has increased “exponentially.”

“I don’t think we would have been able to do the development that we did over the course of the past year or so, and the scaling up that we’re gearing up to do, without 3DEXPERIENCE. It just wouldn’t be feasible. After a week of using the platform, I knew I would never go back.”

Alfred the Robot Sous Chef

Dexai is online at dexai.com.

Highlights of Dexai’s Robot Sous Chef success with 3DEXPERIENCE

• Designing in familiar SOLIDWORKS remains at the core of Dexai’s product development work.
• A digital twin of the entire product is easily accessible to everyone on the team.
• One person’s changes are immediately visible and understood by others.
• No more passing massive files back and forth between designers’ individual devices.
• Cloud-based – there’s no need for a traditional server-based approach.
• Scalable – allows for growth in the number of team members and increases in production.
• Modular – when ready, Dexai began to take advantage of product lifecycle management (PLM) components, such as identifying, assigning, and managing issues, and creating and maintaining an accurate and up-to-date manufacturing bill of materials.

In 1996, a snowboarding injury caused Christian to become paralyzed from the waist down. As an athlete, machinist, and creative and determined problem solver, he started designing equipment to help make life better for himself and others facing mobility challenges. One result is Bowhead, which designs and manufactures off-road adaptive e-bikes and has its home base in Calgary, Alberta, Canada.

Bowhead Shop Floor

Sanket Patil is a mechanical designer and engineer-in-training at Bowhead. He started in the business as a volunteer, passionate about delivering an adaptive biking experience and ready to contribute his skills. Beginning in 2020, he joined the company as a full-time designer, troubleshooting issues found during field testing and improving designs.

Bowhead e-bikes are engineered to order to suit a person’s level of mobility and specific needs and wants. Sanket explained that the whole purpose is to accommodate each unique user, so the design process must follow suit.

Bowhead RX at Trout Lake

“A customer chooses options depending on variables such as their foot size, or the type of seat they prefer, or whether they have use of their hands or back muscles. This customization means we need to manage hundreds of parts, complex assemblies, and hundreds of thousands of possible combinations.”

Better data management became a priority

Bowhead’s first e-bike model was REACH. When they moved on to the RX model, Sanket said they suddenly had a lot of data that couldn’t be managed in a folder system any longer.

In 2020, Sanket was the only one working on CAD regularly. A folder system worked fine at first, but it soon became difficult and time consuming to implement and control revisions. He also lacked detailed design history, and creating multiple files was causing a storage capacity issue.

He had some experience working with product data management (PDM) solutions, but he was wary of the upfront investment that would be required and knew that Bowhead would also need to outsource customization and implementation.

“We had also added engineers working on our designs remotely,” he said. “We had to quickly implement a PDM solution that was flexible and easily scalable as our company continued to grow.”

The path to choosing 3DEXPERIENCE

Bowhead was already involved with the Dassault Systèmes SOLIDWORKS for Entrepreneurs program, so they approached Dassault to talk about their evolving needs and get advice. Dassault introduced Bowhead to 3DEXPERIENCE (3DX) and offered a chance to try the platform and discover its capabilities.

Sanket was impressed. He said 3DEXPERIENCE, and the ENOVIA data management tool in particular, allows his team to manage CAD efficiently and collaborate.

Managing CAD Data in 3DEXPERIENCE

“We run the platform practically out of the box and since it’s cloud-based, we don’t have to worry about maintaining servers or hiring an IT specialist. These are crucial aspects for a start-up like ours.”

Bowhead has since grown to have four engineers on site in Canada and two contractors who connect to 3DX from India.

“It’s easy to involve all the engineers in product development,” Sanket said. “We all work with the latest revision. I can easily redline a drawing, send a change order, and later approve that change. And as the company matures, we are expanding to managing other parts of our operation.”

Beyond CAD data

Since implementing 3DEXPERIENCE, Bowhead has expanded beyond using the original design-based features into project planning and change management features.

ENOVIA Data Management

They have also started using some product lifestyle management tools the platform offers, such as doing full product BOMs for their e-bike projects, which include non-engineering items like harnesses and labels.

“We were in the R&D phase of the RX when we got 3DEXPERIENCE and it really set us up for success in manufacturing. The careful tracking makes the design process transparent to the end user. Every piece of a product’s history is searchable and traceable.”

Onboarding and support from Javelin

Implementing a new technology platform while developing a new bike might have been daunting but Sanket says the software was user friendly and easy to learn. And Javelin – A TriMech Company, which provides and supports SOLIDWORKS and Dassault Systèmes solutions, made sure he and his team were trained and positioned for success.

“Javelin guided us through the setup and resolved queries as they arose. Their service is impeccable and response times are amazing. With their help, we didn’t have a single day of downtime, which is absolutely essential for us to meet our deadlines.”

Javelin has a detailed process for onboarding clients to get them operational and feeling confident quickly. As the main admin, Sanket did a training session over three half days; others on his team joined him for the last day.

He explained that he knew the system could do certain things, but he didn’t know how, and that these were the kinds of questions he posed to Javelin.

“One thing I struggled with was the part-numbering system. Ours was already in place and I didn’t want to change it. Javelin understood the ins and outs of 3DEXPERIENCE and created a process workaround involving file naming, which made our existing system compatible.”

Sanket also noted that he’s glad Javelin and 3DEXPERIENCE are at the helm of Bowhead’s data management and will take care of the increasing complexity they’ll face as the company grows.

“There is no stopping us now – we will continue to innovate and bring smiles to our customers’ faces.”

Bowhead is online at bowheadcorp.com.

Bowhead REACH – adaptive mountain bike

Why is 3DEXPERIENCE proving successful for Bowhead?

• 3DEXPERIENCE Works supplements their existing desktop SOLIDWORKS tools with powerful cloud-based data and product lifecycle management.
• They now have one cohesive system accessible from any device.
• 3DEXPERIENCE Works is ready to handle more (and new types of) users and complexity as the company grows.
• No major upfront capital investment was required, well suited to a start-up like theirs.
• Bowhead has a trusted relationship with their technology partner Javelin.

In 2006, Measurand released its first ShapeArray™, a measuring instrument used to monitor deformation of soil under and around critical structures.

“Ongoing training is a given when you work in tech. You have to keep on top of it. Training is always in the budget – if you don’t invest in training people, you won’t keep those people.”

— Tricia Harrison, Manager of Product Development, Measurand

Silent segments and extension tubes provide flexibility and control when placing ShapeArray™ vertically in a zone of interest.

The real-time data the ShapeArray generates allows engineers to improve safety and reduce risk; save time and money; and make fast, smart decisions. Before automation and data visualization were available, people had to rely on manual measurement. Today, using ShapeArray, real-time monitoring of soil distortion and movement reduces the risk of catastrophic failures.

Applications vary, from measuring soil movement beneath urban construction projects to monitoring geohazards, such as slope instability, in remote locations. The Canadian-made technology protects the integrity of significant infrastructure, such as mining waste containment structures, public transit tunnels, and dams.

Since pivoting from measuring the human body to measuring the Earth, Measurand has grown to more than 70 employees and is a global leader in designing and manufacturing instrumentation for geotechnical deformation monitoring.

SOLIDWORKS training to optimize product development

SOLIDWORKS, sold and supported by TriMech, has been the 3D CAD software of choice for Measurand’s engineers for about 10 years. To ensure that they were using SOLIDWORKS consistently and to its full potential, the team turned to TriMech for a professional assessment of their skills and processes.

Tricia Harrison, Measurand’s Manager of Product Development, said she wanted to identify any gaps and discover ways to improve.

“TriMech’s SOLIDWORKS Training Assessment was a key first step. TriMech’s consultants spent time listening to our people to learn how they typically work and to identify their points of frustration. We knew that each person was working slightly differently than the next. We wanted to establish a baseline, then align the team to do everything in an optimized way.”

Following the assessment, TriMech recommended SOLIDWORKS Essentials training, delivered live by TriMech instructors online, as well as its Custom Properties and Drawings Service. This training focuses on optimizing the entire process of taking drawings through to manufacturing, including using templates and revision management.

“Training is foundational for all of us,” Tricia said. “Some people are advanced users; others are new users. Everyone can benefit from continuous learning.”

Tricia’s team of nine includes mechanical and mechatronics engineers, electrical and embedded systems engineers, and software developers. Initially, SOLIDWORKS was used mainly for creating mechanical drawings and assemblies. More recently, Measurand invested in SOLIDWORKS Inspection, an automation tool that reduces the time needed to record inspection measurements and create documentation.

Valuable learnings add to users’ confidence

Tricia said that her team members are all now confident users, and they no longer spend time trying to learn the features of the software or searching for files. The team was able to standardize design procedures and workflow and reported a variety of other valuable takeaways. One mentioned learning to focus on the core design of each part before combining it into a complicated assembly, which leads to better assemblies and adaptability for future part design changes.

A member of Measurand’s technical services team

The live, online learning environment removed the need to travel and was popular with the team. One trainee said, “The SOLIDWORKS training in small groups really got me excited to have access to an expert who can deal with all of the questions I have, then demonstrate the solutions in a live learning environment.”

Measurand also takes advantage of TriMech subscription service, which includes automatic software upgrades and live technical support. “Investing in the service plan helps us support our people who use SOLIDWORKS,” Tricia said. “That layer of support is worth every penny we are paying. And the TriMech people are easy to work with, right across the board.”

Measurand will continue to seek advice and training from TriMech; in fact, TriMech’s live online SOLIDWORKS Essentials course has been incorporated into the onboarding program for the Product and Engineering teams.“ Ongoing training is a given when you work in tech. You have to keep on top of it. Training is always in the budget – if you don’t invest in training people, you won’t keep those people.”

Making a difference

Measurand continues to grow to meet the demands of short lead times, exacting quality, and continuous improvement.

In recent years, Measurand joined trusted brands RST Instruments, 3vGeomatics, and Syscom Instruments to form Terra Insights—a global platform that offers leading surface and sub-surface data solutions, using underground sensors, cloud-based data, and satellite technology. “We’re leveraging our expertise and technology to deliver not just one product, but a suite of solutions,” Tricia said.

The precise information about underground sagging, sinking, and shifting is being used to reduce uncertainty, protect structures, and reduce construction time and cost. Most importantly, as Tricia noted,

“The instruments we build are used all over the world to protect human life. We are making a difference.”

To learn more about Measurand, visit measurand.com.

“Our custom-build environment requires a solid workflow to keep processes on track. SOLIDWORKS Manage meets our needs for building out processes with the BOM at the centre. You don’t have to limit your thinking to just managing CAD files – you can expand to company-wide business processes.”

— Mike Taylor, Product Development Manager, Phil Mauer & Associates

“Jobs are similar, but with different details,” said Mike Taylor, Product Development Manager. “With each project being unique, and a couple dozen projects on the go, having SOLIDWORKS Manage has been particularly good for us.”

SOLIDWORKS Manage: The left side lists all the record types, routings, work orders, quotes, manufacturing operation types, station names, catalogued build prints, catalogued-customer provided CAD, and of course the PDM object.

What is Manage?

SOLIDWORKS Manage uses the file management capabilities of SOLIDWORKS PDM Professional and adds project, process, and item management.

Organizations like Phil Mauer plan each stage of a project, assign resources and tasks, and attach required documentation – all within the same ecosystem they use to design. When users complete their tasks, project progress updates automatically and is displayed on a real-time dashboard.

While PDM looks after CAD files, Manage contains and connects other data, such as bills of materials, what manufacturing station drawings should go to, and finishing details like paint codes.

SOLIDWORKS Manage process grid view (in this case for routings): shows the flexibility and range of applications for routings. Phil Mauer references this to make sure parts on a released BOM are moving through checking, purchasing and manufacturing.

From paper to digital

Mike explained that before having Manage, if they noticed that a step in the process didn’t happen, they didn’t immediately know why.

“ISO procedures, for example, were in binders and not handy. Someone had to go look up a form or a flowchart of a workflow. Today, it’s no longer a paper exercise. The ISO form is right there on screen, being filled out as you move through the process, and data from the forms can be mined to look for trends and statistics.”

Racking design

Designers once carried stacks of paper from engineering to manufacturing. When they had to make changes, they had to print new drawings and take them to each station, making it difficult to track changes, as well as risking errors and rework.

Using Manage, communication between engineering and the shop floor happens in real-time, digitally, and is easily traced.

Turning ideas into workable options

Mike and his team laid out a detailed plan of what pain points they wanted Manage to solve. TriMech’s technical specialists, with their deep knowledge of the software, translated that wish list into workable options.

“I wouldn’t recommend trying to use Manage ‘out of the box,’” he said. “It’s powerful and flexible – that’s its strength. To get customized workflows, you will want a partner who knows how to implement your ideas into Manage objects and processes.”

Company-wide benefits

Phil Mauer’s people, systems, and departments (including engineering, manufacturing, quality, sales, and purchasing), are now tied into the workflow, or digital thread. Some examples:

• In manufacturing, an export into Excel gives the production supervisor the labour data he needs to make his resource plan and production schedule for the job.
• Upon release of the BOM, purchasing staff can clearly see what materials need to be ordered and when.
• When a project is noted as complete, Manage triggers a customer satisfaction survey. A notice lands in the salesperson’s inbox, so he or she knows to call the customer to check in.
• Mike makes great use of the Manage Live dashboard by showing the real-time status of projects at weekly meetings. Outstanding and upcoming to-dos are discussed.

Another benefit is having clear information about performance against metrics. The quality manager used to enter any design changes made (after production started) into a Microsoft Access database. Now, distribution of the change document happens in a Manage workflow that automatically logs statistics, including how many changes are being generated, the reasons behind them, cost impacts, and the time spent making each change.

SOLIDWORKS Manage dashboard: This dashboard is used to look for issues with part release. It shows relative status of a routing being released in contrast to the stage of the overall project process. For example, are there issues such as parts not released on jobs that should already be in the shop?

Continued evolution and growth

Phil Mauer continues to find new ways to work collaboratively with TriMech. As Mike said, “I have been the champion for Manage, but it’s not just my ideas anymore. Other people have ideas to improve on existing workflows, create new process workflows, and generate new dashboard reports. TriMech knows what we built, and why, and is always there to say, ‘Did you think about doing it this way?’”

Mike explained that overall, Manage is a project management tool that filled a gap between PDM and their ERP system, all brought to life by TriMech.

“It can be hard to get buy-in for a new platform,” Mike said. “But I can tell you that no one here is still asking why we need this. Everyone is informed. No one scrambles. If you want to do more projects with the same people, you have to keep improving processes.”

And speaking of those people, Mike emphasized that he is continually impressed by his team.

“We are always busy, but they are all willing to do what’s necessary to do quality work and grow. Everyone is proud of their work and wants to be better and faster for our customers.”

Phil Mauer & Associates is online at philmauer.com

From job sites to camp sites, farms to fishing holes, DECKED products allow pickup truck owners to improve storage capacity, protection from weather, organization, and ergonomics. The idea is to put more in your truck and retrieve all of it without stretching over the bed rail or crawling over everything you’re carrying.

DECKED products allow pickup truck owners to improve storage capacity, protection from weather, organization, and ergonomics

In business for about nine years, DECKED continues to operate with a dynamic team and start-up culture. In earlier years, they focused on designing and building truck bed drawer systems and accessories; today, they are expanding product offerings, such as a new toolbox that sits behind the cab and includes an integrated ladder.

DECKED has grown to a team of 70 people and is on track to sell 50,000 drawer systems this year. Design, sales, and marketing are in Ketchum, Idaho and manufacturing is in Defiance, Ohio.

Calvin Allan is Principal – Product Development for DECKED. He said a midwestern, Idaho work ethic is built into the company’s DNA.

“We’re proud of our attention to detail and we must get it absolutely right. We could stop at good enough, but we don’t. We always make it stronger and better than we have to. Our company prioritizes that.”

Solving the slowdowns

As the DECKED design team expanded, they were wasting time opening and rebuilding large assemblies. The OEMs supply massive, detailed models of their truck beds. Add that complexity to DECKED’s own complicated models, and integration and manipulation of assemblies wasn’t happening fast enough.

“Customization is our magic and the key to our profitability,” Calvin said. “Our configurable SOLIDWORKS models need to be updated quickly. I knew we needed to go deeper into how SOLIDWORKS is running and learn how to optimize accordingly.”

To investigate, TriMech did a Large Assembly Performance Audit and a PDM Health Check and Audit.

They recommended that DECKED take advantage of TriMech’s Large Assembly Productivity Service, to teach Calvin and his team how the software operates “under the hood” during opening and rebuilding phases, how to identify what causes slowdowns, and how to solve those problems. It was also important for users to learn best practices for creating fast and clean large assemblies.

“TriMech didn’t just do the work,” Calvin explained. “They taught us what levers they pull to make a difference. We learned the implications of how we were doing CAD, such as how display states and section views were affecting our work. Unused elements and suppressed components were creating errors and bloated models.”

Calvin’s team learned that when they don’t need great detail, working with resolved (unsuppressed) assembly components is unnecessary.

“When vendor models come in, there is excessive detail. Now we know that if we don’t need to see a detailed thread pattern, we get rid of it. We didn’t know we had so much control over opening individual parts.”

The team now works faster than they ever have before.

“I’m not exaggerating when I say our opening times are 10 times faster. Files that took 30 minutes to open now open in a few minutes and files that took a few minutes now open in seconds.”

Custom, relevant training

TriMech delivered team training remotely from Canada and it was recorded for anyone who couldn’t attend live (or for future new hires). Even Calvin, an advanced user, learned “golden” tips during TriMech’s training sessions.

“The training was custom to our work, geared toward what we were seeing every day. They didn’t use canned examples. You could spend years doing something one way, never knowing there’s a better way.”

Work faster and reduce errors using PDM features

Calvin also noted that TriMech’s PDM Health Check and Audit revealed areas for improvement. Again, the DECKED PDM system was organized well enough for one person but not efficient when multiple users contribute to the same files.

“TriMech didn’t come in with a prescribed recipe. They said, ‘show us what you’re doing.’ Their audit report recommended improvements, then their services team built them right in front of us.”

Overall, that meant modifying the existing workflow to suit current business processes. DECKED now has a faster, better file search function, automated processes (such as file conversion) using SOLIDWORKS PDM Tasks, and email notifications to speed up drawing review and approval.

“We were using PDM for file storage, like you would use Google Drive,” Calvin said. “We weren’t using it to manage our workflow and we had no gating. Now, our file structure is efficient. It’s fast and easy to find files, see if they are checked out, and understand what stage they’re at. We can tag files to bypass review or demand review. We can see if files have been to the vendor or parts have been released.”

With PDM use elevated, more people at DECKED are beginning to understand how it can be a meaningful tool across the company.

Devote the time to learning

DECKED started benefiting from their investment in training and services quickly, putting new methods into practice right away.

“There will always be emergencies competing for your attention,” Calvin said. “You have to devote the time to learning to be better off in the long term. And TriMech has been a well-oiled machine. They have what I need – the people and processes for deployment and follow up.”

DECKED is online at decked.com.

Damon has patented a 360-degree AI-enhanced Advanced Warning System for Motorcycles called COPILOT™ and designed and built the world’s first shape-shifting electric motorcycle.

The safety system locks onto dozens of objects around the motorcycle and alerts the rider to oncoming threats using LEDs and vibration in the handlebars. The embedded crash detection sensors also collect rider, traffic, and vehicle data and send that information to the cloud. This means that Damon’s system learns from every rider and every situation.

The electronically adjustable ergonomics system unique to the Damon design is called SHIFT™ and is made up of four auto-adjustable points: seat, handlebars, foot pegs, and windscreen. Incredibly, the bike shifts from sport to touring to upright/city positions.

Damon Motorcycles – Halo Bike designed in SOLIDWORKS

Meeting design challenges using SOLIDWORKS

Damon’s strengths are rooted in technology but their mechanical engineering team gets the credit for building their proof-of-concept Halo bike.

They used a combination of 3D scanning, SOLIDWORKS desktop software, and 3D printing to create the unique and tricky components that would allow the bike to transform.

Product Design Manager Raymond Leung said a bike like the Halo had never been built before and it was challenging work.

“We had to build a safe, ridable prototype that would not only have a pleasing appearance but also features that transform. Parts need to morph safely and smoothly without interference.”

Raymond arranged for the basic features of a motorcycle to be laser scanned, then imported the scanned data into SOLIDWORKS. Reverse engineering gave him the base for creating the necessary appearance, as well as for designing mechanical parts.

Raymond said he trusts SOLIDWORKS to allow for multiple designers and engineers to work on a single file, and to handle large assemblies well. His team members often have to work in parallel and his models have more than 500 components. Those models come together to create the main assembly.

Advice on working with large assemblies is one of the ways Raymond has received help from TriMech. He has been using SOLIDWORKS for many years but occasionally relies on TriMech’s depth of expertise.

“TriMech gets back to me immediately with advice about how to solve any problem I run into. It’s convenient for me to visit them in person in downtown Vancouver to show them a problem and get timely help. They also have expertise in working with scanned data and in 3D printing so they bring a lot to our conversations.”

Next up, Raymond will be investigating SOLIDWORKS Simulation to enhance his ability to virtually test part performance, as well as solutions to improve data storage and supply chain management. Damon will also use SOLIDWORKS to design the next generation of the ergonomic system – one that conforms to the unique characteristics of an individual rider for maximum customization and comfort.

Changing the industry and rider experience

Head of Product Marketing Amber Spencer said the Damon team is proud of their progress to date.

“We’ve done so much in so little time, including taking the bike on tour. Our founder and CEO Jay Giraud presented a TechCrunch session and we’ve given media and motorcycle manufacturers a chance to try the bike. Everyone has been blown away. Seeing the reaction on people’s faces, when they ride the bike we created, has been very rewarding.”

Damon’s main purpose is to cause a shift in the industry. Motorcycles are often seen as unsafe, intimidating, and hard to ride.

“We want to see more people enjoying motorcycles,” Amber said. “With our background and tech expertise, we’re able to increase a rider’s safety and comfort exponentially. As we move forward into the future, we will continue to find ways to make the riding experience better.”

Damon’s future also includes securing further investment and business partners, and spreading the word about their innovations to individual riders. Amber said any motorcyclist who is interested can get on a list to test ride the bike and give essential feedback.

“We definitely want people to visit our website and learn more about us. And when you put your name on our beta list, you’ll have an opportunity to test ride and pre-order the Halo bike.”

For more information, please visit the Damon website.

Damon Motorcycles Team, Vancouver BC

Greg is an instrument and toolmaker in the Design and Fabrication Services Branch of the National Research Council of Canada. He works out of NRC’s Victoria location, the site of the Dominion Astrophysical Observatory and the Canadian Astronomy Data Centre.

Greg is part of a team of advanced machinists who build components for Canadian and international scientists and astronomers. Their work involves precision machining to tolerances of three to five microns, using the kind of machine that can engrave a human hair. Finished instruments are shipped around the world to the sites of massive optical and radio telescopes, such as the twin Gemini telescopes in Chile and Hawaii or the Dominion Radio Astrophysical Observatory in Penticton, BC.

When the COVID-19 pandemic was declared in March 2020, an opportunity opened up for Greg to move professional development higher up on his priority list. With the support of his employer, Greg took the time to upgrade his skills in SOLIDWORKS 3D design tools.

Long-time user learns new tricks

Greg is far from a novice user of SOLIDWORKS – he has been using the software for 20 years. He simply knew that proper training would increase his productivity and make his life easier.

“I was self-taught,” Greg said. “I had my own ways of making drawings and parts but occasionally became frustrated with some tasks. I could put a model together using my own techniques but wasn’t necessarily comfortable handing that file off to someone else.”

During training with TriMech, Greg learned valuable tips and tricks.

“I now use tools I didn’t know existed. I used to work through several menus to get to certain functions and now I know the keyboard shortcuts that eliminate those steps.”

Greg learned how to automate repetitive tasks related to components he uses regularly. And instead of using a calculator, he now programs formulas to maintain design intent when a part is modified. He calls the tips he learned for mating assemblies and working with advanced mates “pieces of gold.”

Through training to certification

Greg participated in three of TriMech’s live online training options for SOLIDWORKS users: Essentials, Drawings, and Assembly Modeling. He then added to his list of accomplishments by successfully completing the examinations for two designations: Certified SOLIDWORKS Professional (CSWP) and Certified SOLIDWORKS Professional Advanced Drawing Tools (CSWPA-DT).

“After using SOLIDWORKS for such a long time, it was time to prove my skills,” Greg explained. “Even with years of experience, I never would have passed the certification exams without going through the training courses.”

Greg also prepared for the exams by checking out supplemental training on the SOLIDWORKS website. He picked up a few new skills while refreshing his knowledge before being tested.

Greg Nuspel from NRC with a Kern CNC mill in the shop

SOLIDWORKS online training well designed and engaging

TriMech has been delivering live online training (called JOLT) for years and Greg said that experience stood out.

“The courses are well organized, and are structured to adult learning, which is about making sure we know why the content is important. The TriMech manuals are excellent and easy to work through.”

It takes a little more effort to provide personalization and a sense of community in the online environment. Greg reported that he was a little hesitant at first asking his questions, but he and the rest of the trainees quickly became more relaxed. Eventually they were able to replicate some of the peer-to-peer exchanges that happen in a classroom.

“If we ever had a question that stumped the instructor, he said he’d get us the answer right away. By the time we had done an exercise, he was back with the answer. I’m sure that speaks to the solid support team TriMech has.”

Proof of proficiency

Because of the skills and confidence Greg has gained, he has become much more efficient in completing fixture designs. Also, the engineering team is able to offload the task of detailing drawings, freeing up their valuable time.

“The engineers know I’m certified and can manage their drawings. When we work together more efficiently, everyone saves time. Adding more of my expertise in machining and manufacturing to the design process is an added benefit. My organization’s investment in training is easily recouped in overall increased productivity.”

For now, Greg is satisfied with his two new professional designations. He may continue his learning with some advanced TriMech training in the future.

“I hope to encourage others to do training and certification and find better ways of working. People might have some time to focus on training now; once they get back to the regular grind, they might not take the time to improve their skills.”

With facilities in Nova Scotia, Canada and Maine, U.S.A., Nautel is one of the world’s largest manufacturers of AM and FM radio broadcast transmitters. Since 1969, they have deployed more than 15,000 transmitters in 177 countries. Nautel is best known as the first company to develop a commercially available, fully solid state broadcast transmitter. They also design and build navigational radio beacons, GPS transmitters, weather transmitters, and sonar systems.

As of December 2017, Nautel’s largest transmitter – a two-megawatt AM medium wave system – is on the air at Antenna Hungaria’s transmission facility near Solt, Hungary. It marked Nautel’s largest single installation to date.

Drafting manager Joey Panczyk has been with Nautel for 21 years. He jokes about seeing the drafting process go from sketches on paper napkins to complex designs in SOLIDWORKS 3D CAD software. Since 2003, Nautel has been using SOLIDWORKS products provided and supported by TriMech.

“We needed software we could expand on and grow with, plus a solid provider and partner,” Joey says. “I knew SOLIDWORKS would represent our product in the best possible way and reduce our time to market.”

Joey’s department includes three mechanical designers and two circuit board designers. Over the last few years, Nautel has been ramping up their SOLIDWORKS use and adding features and functions offered by a variety of products in the SOLIDWORKS family. For about a year, Joey’s team has been using SOLIDWORKS for electronics design.

“One of the reasons we chose SOLIDWORKS is the easy interface between it and SOLIDWORKS,” Joey says. “There were hurdles to overcome but at the same time we successfully created the biggest circuit board in the history of our company.”

Nautel also chose SOLIDWORKS because they knew they could count on support from Javelin, support they didn’t have for their previous circuit board software.

“Even when PCB was challenging, TriMech was helpful, and reported any bugs to PCB. We took a chance on PCB because we have such trust in TriMech.”

Multi-product approach meets different needs

Nautel’s designers use SOLIDWORKS mainly for sheet metal design, since 95 percent of a transmitter is sheet metal-based material.

NVLT-GV FM Transmitters

As they have moved into working on sonar projects and complying with the requirements of shipboard mounted systems and military specs, they have been using SOLIDWORKS Simulation to test their designs at early stages, instead of having to use an external shock and vibration tester right away.

Joey also credits SOLIDWORKS Simulation for giving his team the ability to reliably test air flow, particularly important when working on small scale projects.

He recalls the old days of making models with cardboard and using “the brute force method” to see how a design would react in real life. Today, Simulation allows them to quickly test, catch bugs, and improve the design.

Another SOLIDWORKS product, Composer, has given Joey and his team the ability to present assembly drawings in three dimensions. Assembly drawings were always on paper – three dimensional drawings, but presented in two dimensions. Nautel now places a monitor at each work station along the assembly line for an FM power module. Employees interact with the screen, rotating or pulling apart a drawing, or accessing health and safety data. They can also view instructions for working with parts provided by third party suppliers.

“They have links to the information they need right at their fingertips,” Joey says. “We’re limiting our paper use, and no one has to flip through a book anymore. It has been well received.”

Composer also generates publications to outline how to operate and service Nautel transmitters, including images and 3D animations.

“This worked well for us in Hungary,” Joey notes. “We deliver all over the globe – the Middle East, Europe, India – we need documentation with fewer words and more images.”

Joey says presenting animations to potential customers allows them to understand the product better at an earlier stage in the sales process. For example, instead of seeing only a top-down view of the proposed floor plan, customers can see – in 3D – exactly how the equipment will fit in their space.

Nautel’s bid to win the business in Hungary was strengthened with images and 3D animation.

“For the first time in 40 years, they went shopping for one of the most powerful AM transmitters in the world and they take great pride in their equipment. We won them over and they took a chance on us with a $4-million project. 3D technology helped make that happen.”

To control data and improve collaboration, Nautel also uses SOLIDWORKS Product Data Management (PDM). PDM helps the team manage files and workflow. It offers a secure vault with controlled access – everyone involved can access the information they need, while files are protected by automated version and revision control systems.

“Sign-offs are easily recorded, and everyone knows what stage a project is at, reducing the risk of building the wrong part,” Joey says. “And not everyone has a super computer to manage full design files, so being able to generate a PDF for our manufacturing department is important.”

Joey has been a champion for SOLIDWORKS for years. He says Nautel is packed with people interested in the latest and greatest, and in finding the right tools to help employees be faster and better.

“We’ve invested a lot in SOLIDWORKS to get the benefits of building stronger and better products. We can make design changes in seconds, generate images documentation, easily explain designs to others, and just get to market quicker.”

Results for Nautel

• Using a variety of products in the SOLIDWORKS family is meeting Nautel’s unique needs in equipment design, testing, production, deployment, servicing, marketing, and sales.
• Using SOLIDWORKS Simulation software, Nautel’s designers can test air flow and shock and vibration in-house, and earlier in the design process.
• SOLIDWORKS offers easy integration between electrical and mechanical design and is well supported by TriMech
• Visuals and technical documentation created in SOLIDWORKS Composer, using existing CAD data, help Nautel stand out from the competition and allow them to communicate better across cultures.
• Data management tools provided in SOLIDWORKS PDM help everyone at Nautel maintain up-to-date files, manage workflow and sign offs, and avoid costly errors.

Doran Avivi is a Staff R&D Engineer at Baylis. He said his team contributes to creating new, innovative technologies for cardiologists.

“Our devices give surgeons minimally-invasive access to the left side of the heart. When the surgeon can work more efficiently, we’re enabling them to provide better care for their patients.”

Doran and his colleagues continually improve the design and manufacturing processes for their devices, and efficiency and productivity must remain at a high level. One key way they do this is through ongoing training.

Every 3D model for every product designed by Doran’s team is created using SOLIDWORKS 3D CAD software. To build skills and knowledge in the full suite of SOLIDWORKS tools, Baylis turns to TriMech; in particular, Doran appreciates the flexibility of TriMech’s corporate training program.

Baylis Medical VersaCross® Steerable Sheath – SOLIDWORKS model

Flexible SOLIDWORKS training

TriMech’s corporate training is easy for clients because it’s one order, one purchase, yet includes 20 or more flex training days that can be used by any employee, in any location, to attend publicly offered in-person or live online courses.

Some Baylis designers take advantage of SOLIDWORKS Essentials training, to get better acquainted with the software. Others, like Doran, take advanced courses in SOLIDWORKS Simulation, SOLIDWORKS Drawings, and SOLIDWORKS Advanced Part Modeling.

“TriMech has a huge list of public courses to choose from. It just depends on who is looking for training at the time and how much experience they have.”

Doran adds that the flexibility in scheduling is helpful because they can send just one or two people, instead of managing the downtime that comes with having 40 people training at one time. He also likes the half-day online options because trainees can keep up with their regular work.

Growing in popularity

Baylis is on its third year of investing in TriMech’s corporate training days. In 2020, they chose 20 days; in 2021, they increased to 35.

As the engineers started taking courses, first discovering how easy it was for them to choose a course and get approval quickly, then experiencing the quality of instructors and course content, demand began to increase. Plus, the overall team continues to grow, with new talent arriving.

“There are many ways training makes us better,” Doran said. “Mainly it’s learning best practices to do CAD properly and getting comfortable with any new features. We always want to create 3D models quickly, iterate quickly, make a better product, and get to market faster.”

Even for an experienced user like Doran, there’s always more to learn.

“CAD is time consuming by nature. I make a note of all the shortcuts so I get more efficient. I also like practising on a real case. I’m a visual learner who learns by doing.”

Baylis came to TriMech from another provider several years ago and Doran said he enjoys SOLIDWORKS flexible training and working with the people at TriMech. “TriMech has great customer service. The instructors are friendly and knowledgeable, and they answer your questions live. They send training manuals beforehand so you can prepare or look up content afterward, and the courses are thorough and in depth.”

3D printing aids medical product development

Baylis also has four Stratasys Polyjet 3D printers, which the team uses during product development to make prototypes and test designs. It’s another reason why knowing the ins and outs of SOLIDWORKS is so important – designing properly for additive manufacturing.

Doran Avivi with their Stratasys 3D Printer – an Objet30 Pro

Baylis Medical Investing in people

Baylis is serious about investing in its people through professional development, and managers all have development plans for their team members.

“Baylis recognizes that the growth of the company depends on the growth of the employees,” Doran said.

Baylis is online at baylismedical.com.

TriMech’s public training schedule includes courses in design, simulation, data management, CAM, electrical, and communication. Learn more about our training and consulting solutions.

TriMech customer Ka’ana Wave Co. has designed and built a wave machine that can be installed in an existing body of water or new custom build, such as a community swimming pool. To produce a wave for a surfer, the Ka’ana machine shapes a flow of water as it passes through the contours of a shaping head. With interchangeable shaping heads, and the ability the articulate the pitch of the shaping head, one machine can create a variety of wave forms and flow rates.

See a demonstration of the Ka’ana machine: 

Jamie Watson is Ka’ana’s CEO. He said he was first introduced to SOLIDWORKS 3D design software because it was recommended by their manufacturing partners.

“When we had our minimum viable product and started communicating with our engineering firm and steel and fibreglass fabricators, they all pointed us to SOLIDWORKS.”

TriMech suggested that Ka’ana Wave apply for a SOLIDWORKS program that supports entrepreneurs and startups with a year of free access to 3D design software tools and the SOLIDWORKS online community. Ka’ana’s application was successful.

“Support from SOLIDWORKS was vital to our success,” Jamie said. “As a startup, resources were tight.”

Previously, Ka’ana had been using a lightweight software to design small prototypes that were produced on a desktop 3D printer. When it was time to meet the industry standards of engineers and traditional manufacturers, using SOLIDWORKS was key.

Analyzing designs before production

Upon completing the free one-year term offered by the SOLIDWORKS program, Ka’ana purchased SOLIDWORKS Premium.

Surface modelling is especially important at Ka’ana. Jamie said the team has worked with a thousand iterations of the wave machine’s shaping heads. Being able to easily evaluate surface features, well before moving to creating fibreglass parts, has been valuable.

Jamie appreciates that SOLIDWORKS makes communicating with Ka’ana’s partners seamless. He is also benefitting from their experience. In one case, Ka’ana’s fibreglass manufacturer told Jamie that a part’s design needed to be modified before production. They provided instructions to help Jamie make the change, which helped him add to his knowledge of the software.

“I am so impressed with the SOLIDWORKS community,” he said. “We have access to an extensive public knowledge base. I’ve watched YouTube videos with qualified teachers and relied on TriMech’s technical blog articles for troubleshooting.”

Jamie reports that TriMech has been “fantastic from the get-go,” helping Ka’ana apply for free software, then supporting them along the way.

“I can call anytime to ask questions, and I have also benefitted from their expertise in 3D printing.”

High quality renderings help the marketing effort

Ka’ana had planned to launch at a large amusement and attraction industry trade show in the U.S. in November 2020. When the pandemic made that impossible, they quickly ramped up their marketing efforts, creating new materials and methods. Their live product demo in a test pool in Chilliwack proved to generate a lot of excitement for their product.

Ka’ana park overview rendering

Renderings and animations created in SOLIDWORKS are helping potential customers understand how the Ka’ana machines work and how they would look and function in real life settings. These include resorts, waterparks, amusement parks, municipal or private swimming complexes, and mixed use developments combining shopping and entertainment attractions.

The small and medium sized units can produce waves up to six feet tall and will be ready around the end of 2020. Larger units, coming in 2021, will produce waves up to 12 feet tall.

The Ka’ana machine is a crowd pleaser, and suitable for all levels of surfer. It’s unique because when you turn off the machine, your swimming pool is still there for regular uses.

Ka’ana machine rendering

Making surfing accessible is the goal

Jamie is most proud of the mission his team of nine lives by – to share the fun experience of surfing. On a wider scale, he hopes to support the board sports industry and retailers, who are challenged by seasonal highs and lows.

“Snowboarding depends on climate. Until now, surfing has depended on geography. We are using our technology to make a great wave, challenging the theory that surfing happens only in the ocean.”

Surfing Machine Project Results

• One year of free access to the suite of SOLIDWORKS 3D design software allowed Canadian startup Ka’ana Wave to begin using the industry standard tools expected by all of their manufacturing partners.
• Ka’ana continues to take advantage of the technical expertise of TriMech specialists, as well as the SOLIDWORKS community, to learn how to maximize their use of the software.
• Being able to easily evaluate surface features, well before moving to creating fibreglass parts, has been valuable, considering Ka’ana has worked with a thousand iterations of the wave machine’s shaping heads.
• Renderings and animations created in SOLIDWORKS are helping potential customers understand how the Ka’ana machines work in real life environments

To learn more about Ka’ana Wave, visit kaanawaveco.com.

“Congratulations, Rob!!

You have been awarded DELMIAWorks Technical Sales Training Certification. You also hold the honour of being the very first person to accomplish this…and you are in a great position to help take DELMIAWorks to market.”

Sent via email by Jim Hoium, Director, Partner Enablement, DELMIAWorks

DELMIAWorks combines engineering resource planning (ERP) and a manufacturing execution system (MES). With one single platform, you see a clear picture of the factory floor. Real-time process monitoring allows you to make decisions quickly and be confident that production and quality control is being executed well.

Rob and several others on the Javelin team went through various phases of “boot camp” training to be able to work confidently with manufacturers considering a new ERP/MES solution.

Rob’s own training experience was eight weeks long, a combination of hands-on training and remote learning. Courses delved deeply into the functionality of the software, from the overall product roadmap to target areas like managing inventory and data flow. He spent another three weeks preparing and performing mock product demonstrations to prove his product knowledge was solid.

Rob Hauser DELMIAWorks Technical Sales Certification

Digital transformation is being accelerated

In usual times, there is a small slice of time when a manufacturer is considering adding or changing an ERP or MES. Given the challenges of 2020 however, Rob said it is the perfect opportunity to look for efficiencies and new ways of working.

“Digital transformation is being accelerated. Manufacturers may be facing lost margins and looking for savings. Now is the time to reduce rework and waste. And if you happen to be a bit slower than usual, you’ll have time to carefully list the needs and wants of each department.”

Understanding that moving to a new ERP/MES is a big undertaking for manufacturing leaders, Rob says the most important thing he can do is fully understand the customer’s unique needs, whether they operate a small, single-site or several large plants around the world.

“DELMIAWorks covers the entire process, from the moment you receive a sales order, through scheduling, production, and shipping. We spend a lot of time learning about a manufacturer’s strengths, challenges, and needs, or what functionality they are missing right now. Then we work to meet those requirements.”

End-to-end monitoring in real time

The DELMIAWorks combination of production management and production monitoring, along with end-to-end visibility, provides extraordinary data and analysis. Rob noted one key example – real-time reporting from the factory floor.

“Think of the efficiencies gained when you know a machine is running slower than usual or the scrap rate is increasing. The DELMIAWorks dashboard shows all the processes on the floor. You can see machines down for maintenance, and immediately move orders to different machines. Wouldn’t it be fantastic if you were notified in real time and not have to wait for a report at the end of a shift or the end of a week? Think of the savings in material, labour, and rework costs if problems could be corrected before producing non-conforming parts.”

The integrated ERP/MES system contributes directly to a manufacturer’s ability to continually make quality products, be agile enough to meet diverse customer needs, and work with speed and efficiency – all more critical than ever before.

Interested in DELMIAWorks?

Contact us for more information about this scalable ERP and MES solution.

DELMIAWorks Partner

Based in Waterloo, Ontario, Aeryon design Small Unmanned Aerial Systems (sUAS) for a range of applications around the world.

Aeryon Labs Glen Johannesson

Aeryon had its start in 2007, with the release of the Scout in 2009. The founders’ original idea was to develop a tool for collecting aerial imagery. The commercial market wasn’t quite ready to invest, but the military was, and they were the first to purchase the technology. By 2010, police services had begun to use the drones in traffic collision reconstruction. Taking photographs from the air helps with accurate measurements and capturing visuals like skid marks. Officers report that investigations that used to take two hours now take only 15 minutes, allowing them to clear scenes quickly and avoid the economic and social impact of road closures.

Designing for flight

Glen explains that designing a drone is about opposing needs – it has to be strong, but lightweight enough to fly. And of course, you have to be able to make it before you can make it fly.

SOLIDWORKS® is the 3D design tool of choice for the engineers at Aeryon. They choose TriMech to provide and support the software, and ever since a smooth initial implementation, have expanded their SOLIDWORKS user base.

The benefit of clearly seeing designs in very early stages translates easily to savings, both in time and dollars.

“It can cost up to $15,000 to make a mold, so if we have to modify the design, it’s expensive,” Glen says. We used to cross our fingers a lot. If we can catch an issue early in SOLIDWORKS, and save that money, the software pays for itself in one situation.”

Not only did reducing the number of molds save money, particularly important in the early days when sales were just beginning to ramp up – but Glen was also able to combine parts, generating more savings and optimizing the aircraft’s weight and performance, and passing those savings and performance benefits on to the customer.

Picture of Elora Quarry from the sUAS

Lightweight and custom

The drone design is a complex, integrated system of hardware and software, designed to be easy for the pilot to operate using a tablet controller. It is built so that the propellers and legs can be transported attached to the aircraft or assembled in the field without tools, and if it takes a hard landing, these components can be easily snapped back on.

Aeryon Sky Ranger Package

Aeryon sUAS are in the five-pound range, with a bit of variance based on the weight of the camera payload, which is 10% of the craft’s total weight. Commercial customers operating in Canada and the U.S. are certified to fly based on certain weight classes so designing to keep it lean and light is critical.

Glen and his colleagues design all the components in SOLIDWORKS and assemble and test them in house. Aeryon’s partners make the molds and components.

Customization is key. Different customers have different requirements for the unit, from thermal sensors, to zoom lenses, to air quality measurement equipment, to the highest levels of encryption for security. Aeryon aircraft fly in 35 countries around the world, so other customizations ensure safe operations and compliance to airspace and government regulations.

Customer-driven drone design

Glen says working at the forefront of a new industry means working closely with users and potential users to advance the product and meet the current and future needs of customers. In the first year or two especially, customers were curious – and hopeful – about the applications.

“In the beginning, we needed feedback to help the customer be successful. Customers would say, ‘can you make it do this?’ and often we hadn’t even thought of ‘that’ yet. Our customers have helped to determine the functionality.”

It’s also been important for Aeryon designers to react quickly to customer problems in the field. One customer needed to fly close to high-voltage power lines but was unable to because of the sensitivity of the aircraft’s magnetic sensor. The team worked all weekend to redesign a new version of the drone that would briefly ignore the interference and the customer was able to get the job done.

Powerline Inspection

“They couldn’t believe we reacted so quickly, in just a few days,” Glen explains. “We used SOLIDWORKS to quickly modify the design to accommodate those unique needs.”

Glen also appreciates being able to show people detailed renderings on screen. Even if you’re not a mechanical engineer, you can easily see what the aircraft system is going to look like. Aeryon has even used rotating SOLIDWORKS images in a corporate video to help people understand the behind-the-scenes drone design process.

SOLIDWORKS renderings

“I can’t imagine doing this without SOLIDWORKS,” Glen says. “I used to start a design with pen and paper. Now, with the ease of sketching, assembling, and building in SOLIDWORKS, I just dive right in, even at the concept level.”

To learn more about Aeryon’s drone design, visit them online at aeryon.com.