Welcome to the latest Frewer Engineering newsletter.

This month’s edition showcases our explicit analysis capabilities, the intricacies of composite failure, our recent involvement with the University of Surrey, and a placements perspective on life at Frewer.

Simulating Dynamic Problems with FEA

At Frewer we leverage explicit finite element analysis (FEA) to solve complex engineering challenges for our customers. Whether transient structural analysis or fluid structure interaction, our expertise enables us to provide accurate, actionable insights for critical designs.

Explicit analysis is particularly effective in dynamic, highly nonlinear problems where traditional static methods fall short. Our deep understanding of material behaviour, including metallics, composite, plastics and hyper-elastics allows us to navigate elaborate analysis cases with confidence. With our advanced simulation capabilities, we mitigate risks, optimize designs, and accelerate development cycles, delivering solutions that save time and cost. When precision matters, we provide the clarity needed to make the right engineering decisions.

Understanding & Preventing Composite Failure

Composite materials offer high strength-to-weight ratios and tailored properties, but their failure mechanisms are complex. Unlike metals, which typically fail through yielding or fatigue, composites can experience multiple failure modes, including fibre breakage, matrix cracking and delamination. These failures often occur due to a combination of loading conditions, defects, and environmental factors.

To ensure reliability, Frewer Engineering utilises FEA employing a range of advanced failure criteria for assessing the performance of a composite component. Ply-level failure criteria, such as the Tsai-Wu and Hashin criteria, allow us to predict failure based on stress interactions within individual layers as one example.

Frewer has extensive experience in applying these advanced techniques across a range of industries including aerospace, marine, defence and Formula 1, delivering high-performance solutions to challenging problems. Whether it be optimising component stiffness or reducing weight, our multi-disciplinary team provides the expertise needed to provide a tailored composite design & analysis solution.

The Frewer Problem Solving Workshop

At Frewer, we have strong ties with academic institutions for both innovative research projects and recruiting the best and brightest engineers into our advanced design & analysis team. This month, Kristian, Dan & Milan gave a guest lecture about effective problem solving in engineering with our colleagues at the University of Surrey. The team focussed on demonstrating how to properly define a problem & it’s requirements; how to generate ideas in a structured yet creative process; and how to down-select and critically analyse concepts before presenting them to a stakeholder. This was a fantastic opportunity to contribute to the academic community & engage with final-year mechanical engineers to help develop skills that we hone consulting for varied projects across a range of industries.

Life at Frewer, From a Placement’s Perspective

Frewer Engineering stands out as an organisation that fosters continuous learning and professional development. From the moment I joined, I was immersed in a dynamic environment where each day presented new opportunities and challenges. One of the most rewarding aspects has been the wide range of projects available, from programming to hands-on engineering tasks.

A significant portion of my work has involved learning and utilising programming languages to enhance efficiency and accuracy in data analysis within Excel. The emphasis on automation has not only streamlined workflow processes but has also deepened my understanding of computational problem-solving and optimisation techniques.

Etido E.

I have been involved in structural analysis projects, CAD tasks and CAD drawing assignments. These experiences have broadened my technical expertise allowing me to develop a strong foundation in engineering design and analysis. Structural analysis and FEA are often used together to ensure robust and accurate results. By integrating FEA with traditional structural assessments, I have been able to evaluate stress distributions, material behaviour and overall component behaviour more effectively. I have found the combination of both methods is crucial for validating engineering designs and ensuring safety and reliability in real-world applications.

Suraj M.

Throughout my time at Frewer, I have found immense support from both my team leads and line manager. Whenever I encountered challenges or was unsure about a particular approach, they were always available to guide me through, offering insights that helped me navigate complex problems. Their involvement and encouragement have been instrumental in my professional growth, reinforcing my confidence in tackling new and unfamiliar tasks. Knowing that I have a reliable support system has allowed me to take on more ambitious projects with a sense of assurance and enthusiasm.

Overall, my time at Frewer Engineering has been characterised by an enriching balance of technical challenges, firsthand experience, and team collaboration. The exposure to structural analysis, programming and CAD modelling and participation in impactful projects have all contributed to my professional development. As I continue my journey with Frewer Engineering, I look forward to further honing my skills and contributing to the company’s ongoing success.

Sharwa M.