CAD Design Review & Optimization Protocol
Review and optimize CAD designs with AI-driven FEA insights
What You Can Do
This skill analyzes CAD models and FEA results to identify design inefficiencies, stress concentrations, and manufacturing constraints. Claude provides actionable optimization recommendations, material substitutions, and cost-benefit trade-offs to accelerate your design iteration cycles. From concept review to final refinement, you get expert-level design feedback in seconds.
Features
Evaluate CAD geometry for structural weaknesses, ergonomic issues, and assembly complexity
Assess stress distributions, safety factors, and thermal/fluid simulation outcomes
Identify high-stress regions and recommend fillet radii, reinforcement strategies, and geometry refinement
Suggest material substitutions and topology changes to reduce weight while maintaining performance
Flag design features that may cause machining issues, casting defects, or assembly problems
Compare design alternatives on performance, manufacturability, cost, and lead time
Generate prioritized design change recommendations based on impact and implementation effort
Example Output
Design Review Summary
Model: Housing Assembly v2.3
Key Findings:
- ✅ Wall thickness (2.2mm) adequate for injection molding
- ⚠️ Stress concentration at corner radius R=0.5mm (peak: 285 MPa)
- ⚠️ Ribs support edges but interior cavity spans 80mm unsupported
Optimization Recommendations:
- Increase fillet radius to R=1.5mm → reduces peak stress to 165 MPa (42% reduction)
- Add center rib (1.0mm tall) → improves modal frequency from 127 Hz to 312 Hz
- Switch to PA66 GF30 → 18% weight savings vs. current ABS (95g → 78g)
Manufacturing Impact: +$0.08/unit tooling, -15 seconds cycle time
Revised Estimate: Performance ↑22% | Cost ↑3% | Lead time -2 weeks
What's Included
- Design Review Template: Structured checklist for geometry, manufacturability, assembly, and cost analysis
- FEA Report Generator: Automated analysis of FEA solver output (ANSYS, COMSOL, Nastran, etc.) with key takeaways
- Optimization Recommendation Engine: Prioritized list of geometry, material, and process changes ranked by impact/effort
- Manufacturing Constraints Checker: Flags injection molding, CNC machining, sheet metal, and casting design violations
- Material Selection Guide: Comparison matrix for common engineering plastics, metals, and composites with trade-offs
- Cost Impact Calculator: Estimates tooling, material, and labor cost deltas for each recommended change
Who It's For
- Mechanical Engineers
- Design Engineers & CAD Specialists
- Product Engineers in manufacturing
- Manufacturing Engineers evaluating feasibility
- Automotive & aerospace design teams
Best For
- Mid-stage design reviews before tooling
- FEA result interpretation and validation
- Rapid design iteration and optimization cycles
- Material and manufacturing trade-off analysis
- Cost reduction and weight optimization projects
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