CCI’s technical centre, Isatec, has utilized finite element modeling to enhance product development efficiency. Isatec’s developments include sheetforming simulations, 3D simulations of cosmetic appearance, and improved finite element analysis for random vibration fatigue. These techniques were originally developed to improve light shield design and development. That work—presented at ISAL 2007—was applied in the development of a stamped reflector for a halogen fog lamp which is currently in production.
FEA is used in combination with material and process data gathered over 5 years to create a robust forming process for reflector components. The result is a component with the requisite dimensional stability equivalent to more costly die castings.
Isatec also provides a patented method of using strain analysis to predict surface morphology providing three dimensional models of surface reflectivity. Considerable research and development has also been aimed at addressing the shape setting of the reflector.