As you enter the building, a large winding staircase rises up through the spacious open atrium. The stairs appear to float in the air. It is the centerpiece to meet guests as they enter.
Such impressive architecture captures the eye and the imagination. And while they are beautiful, today we will focus on the engineering that accompanies the art and architecture to create that appearance.
One of our customers is a large engineering firm that focuses on interesting features for commercial buildings and similar structures. They design and construct large, complex projects – usually one-offs that provide amazing aesthetics while performing the needed function.
You may have seen their work – and don't know it.
On a few interesting projects, Synthesis was invited in an Engineering Design Consulting role to work alongside their very capable engineering team. We were asked to assist with some specific mechanical design elements.
While keeping the details generic to protect the intellectual property of our customer and the project owners, there is a lot to learn about the engineering process and our role in design consulting.
A Complex One-Off Design Challenge
The business of engineering for a one-off unique project on this scale presents some interesting challenges. To begin, the designs are always new, and that requires careful anticipation of all the connecting design aspects. Then, there is little room for error because there is only one, and the cost is often in the millions of dollars.
So, how does this company stack the deck in their favor?
First, these folks are good at what they do, and very capable in their field. They have a lot of experience, and they are a bunch of really smart people.
Second, they identify where they can use assistance, then bring in others with experience that complements their own. That is where Synthesis sometimes fits.
Where Synthesis Fits Into The Team
It is an honor to receive an invitation occasionally for this kind of engineering design consulting. Our input is not usually in the aesthetic area, as the artists and architects have already defined that. Our job is to assist in making it happen in ways that are safe, robust and functional.
Normally, this customer requests our involvement in only a small part of the engineering. We support their tasks in an engineering design consulting role to help answer key questions, to innovate and find ways to accomplish a unique function, or develop specific mechanical engineering elements.
For the stairway above, they asked us for design concepts for the brackets and structure supporting each stair tread. It had to be encapsulated with the tread, low profile, and effectively invisible. Yet, it had to support several people at a the same time. Enticing.
Design Innovation is one of our fundamental talents, so we fit this need well. We provided two creative concepts, along with the analysis, CAD models, and our assessment of the alternatives. Interestingly, I saw the renderings, and much of the design direction, but I was not privy to the final location, so I don't know where the staircase finally appeared.
Much of their business is in the Civil Engineering arena, and we are not Civil Engineers. However, when creating something new and unusual, the project needs often blur the lines between engineering disciplines.
Whether it is analysis of a beam (or stair) structure for deflection, or a motorized system for movement or containment, physics define the work.
The fields of Mechanical Engineering are vast, and as they intersect other areas, projects benefit from collaboration. For this customer, the work is often a blend of Civil, Structural and Mechanical design.
What The Design Consulting Work Includes
In design consulting with this and other customers, we almost always work with a team to flesh out ideas and analyze possibilities. This may start with discussing ideas or brainstorming with concepts, then separating to analyze or model promising options for further team evaluation.
Depending on the need, our contributions may include:
- Creative concepts for accomplishing something unusual.
- Engineering analysis to evaluate a direction or increase confidence in the design.
- Initial CAD modeling to explore concepts and check viability.
- Mechanical feasibility studies and drive system design.
- Perspective for balance in project expectations.
- Scale model prototypes to demonstrate concepts and improve communication.
- Demonstration hardware to show how a system works and how people will interact with it.
For one project with this customer, we designed and built a demonstration unit so the end customer could see how everything works before committing to the full design.
The demonstration unit was effectively a custom machine. We created a shielding mechanism to block light and visibility when needed, then to open in a way to hide the shielding when not needed. The system required a unique structure, a pair of synchronized drive systems, and a method for control.
At Synthesis we did the full design and analysis, then built the demonstration unit. Some of the panels were made of acrylic so the internals could be seen in operation.
Other times, our role is simply input and perspective.
That is part of the value of engineering design consulting. A capable engineering team does not need outside help with most of the project, but sometimes the right outside experience brings the perspective needed for one aspect.
A third project we did with this customer involved moving a massive structure to cover or uncover a theater stage. The end customer wanted an open air stage – when the weather is good. They also wanted the ability to cover the stage when the weather turned.
The small contribution from Synthesis was a conceptual design for the drive mechanisms with inherent synchronization to move the cover sections smoothly and in synchronization. We worked with their engineering team to define the motion and covering segments, then to integrate the drive mechanisms into the aesthetics.
When Outside Engineering Help Makes Sense
If you could increase confidence in your design direction, or find innovative, elegant ways to achieve unique product functions, would you do it?
Calling on the experience of Synthesis for design consulting is one ingredient in success for some of our customers.
Fresh perspective is one proven way to achieve both of these objectives. It expands the conversation, brings additional perspectives, and can help avoid problems others have already solved.
Outside engineering input can be particularly useful when:
- A design crosses into areas the core team does not work with every day.
- A new mechanism or system has several possible directions.
Fresh ideas or a creative approach are desired. - The cost of discovering a problem late is high.
- Analysis or CAD work can help evaluate an idea before committing to it.
- A prototype or demonstration can prove a concept or improve communication.
- A different perspective is needed to build confidence or see opportunities.
Our experience spans numerous industries in both design and manufacturing, so we have a wealth of knowledge to draw from. We combine experience with creativity, adapting previous concepts to new uses. Cross-pollinating ideas from one industry to another is powerful for innovation. This is one area where engineering design consulting services become especially beneficial.
For this customer, our outside perspective helps answer important questions to build confidence and accelerate progress.
The objective is not to replace a wonderful engineering team. It is to add the experience needed for a question at hand.
Engineering Design Consulting With Synthesis
Which form of Engineering Design Consulting do you need? Sometimes we bring creative ideas about how to accomplish something. Sometimes we provide analysis, CAD modeling or design direction. Other situations require a prototype or demonstration to prove a concept before a larger investment begins.
How you interact with Synthesis completely depends on the need.
In the examples above, their engineering team took the engineering we did and carried it into their final design. They wanted our input for creative concepts and to develop portions of the design to a point where they could run with them. That is a perfect application for engineering design consulting.
Of course, Synthesis is not the perfect fit for every situation. Yet, if you are considering outside engineering help, it is worth asking. You can read "How to Find the Right Engineering Consultant", then the follow-up article about making the Consulting Relationship A Success.
Or, learn more about our Mechanical Engineering Consulting services and the other ways Synthesis can help solve difficult design direction and engineering problems.
Several more case studies on engineering topics are in the Library for you to read. Thank you for visiting.