Product Optimisation Solutions

Product optimisation is the practice of making changes or adjustments to a product to make it more efficient, cost effective, desirable or innovative to give it a competitive advantage within the market.

Whether it’s a modification to an existing design, or the design of a brand new product, the team at PES can offer our clients a range of optimisation solutions to maximise the performance of a product within your budget.

Our use and applied knowledge of advanced technologies allows us to identify opportunities for cost, weight savings and manufacture, building these into the product design at an early stage.

Our engineering expertise, knowledge and problem solving ability are complimented with tools, simulation software and processes including:

Using the latest tools and techniques, PES is able to optimise the design of a new product, minimising requirements for expensive, iterative analysis and testing, and maximising performance and profitability.

Whatever your project, the team at PES have the skills and experience to help you to optimise an existing product or a new concept. Please contact us for an informal chat to talk us through your requirements, whether a quick turnaround or complex advanced engineering design projects. We will be able to deliver you a solution.

With ever increasing advancement in computer technology, optimisation is being increasingly applied to support product development and manufacturing.

Manufacturing industry is reaping the benefits of utilising optimisation in a number of ways including improving product performance and reducing manufacturing or life cycle costs.

The most important part of optimisation process starts by the team sitting with our client and reviewing the physical and market environment in which your product is operating. During this review we also look to define the parameters and key performance indicators (KPIs) of the project. This is crucial as the nature and pedigree of our business, working in high performance and competitive environments, is to continually evolve and maximise the performance of a product or equipment, keeping it at the leading edge within its environment. It is therefore crucial we review what optimisation looks like for the client, define the performance improvements and the time scales and budget to be delivered against.

The optimisation review process can also be used at concept or early design stage, ensuring that the idea is designed to be a as competitive and technologically advanced within its market. Once we understand the key challenges we can tailor a project to budget and timescales. This was the Formula one ethos that once the new part was on the grid it was classed as obsolete. This is certainly very true within other markets and as soon as a product ‘hits the market’ the next product in the evolution chain should be already in planning.

During this initial stage we get to understand and define what ‘performance’ means to our client. To give you an understanding of the KPIs we review here is a list of some of the opportunities we consider:


This could be by reducing the overall cost of the product or moving it into a premium band and therefore driving greater market value and optimising profit.

Material selection:

Reviewing weight, strength, durability, aesthetics and also trends, fashions and availability

  • Carbon footprint requirements

What is the clients ethos and mission in relation to carbon reduction and product sustainability

  • Manufacturing processes

Either through reduced timescales and operations, greater efficiency or simplifying the process, if that is what is required, to ensure that your team, or manufacturing partner has the capabilities to reproduce multiple parts consistently and effectively, reducing wastage of time material and training costs.

  • Data capture and digitisation of legacy parts

If the equipment or product was designed by the traditional drawing method, pre-digitisation, then before you can start any optimisation process we would have to White light scan (WLS) the product and transfer the image to CAD to produce a fully functioning digitised model. Once this data has been captured we can then start to manipulate the model and run simulations.

  • Data capture of other comparable products

Competitiveness is everything and therefore bench-marking, your current product or concept, against your nearest competitor is something that can save you time money and also help to de-risk your project giving it a great opportunity for success when going to market. You of course cannot just ask for this information and therefore we would capture the data using our WLS as with a legacy part.

  • Product Evaluation and Simulation

Using the CAD data of the product we can run this information through a number of simulation software, including CFD and FEA, to optimise the performance and therefore reduce cost and risk ‘downstream’ before moving to the pre-production phase.

  • Product testing

Some clients prefer to carry out testing in an environment that more readily replicates the physical environment in which the equipment will operate. Also physical testing may also be a requirement before the product can be released to the market. We can manage a testing program e.g wind tunnel testing. In some cases the testing process is used by the client as a powerful marketing tool.

  • Rapid prototyping (RP) and Rapid Manufacture (RM)

The greatest advantage of RP and RM and utilising this technology in the prototype development stage is that we can create a physical model of the part. This can be used to carryout testing and evaluation before moving to a full operation prototype. It also allows the client and the team to review and re-evaluate the design in a physical form saving potential costs down stream. Rapid Prototyping, Rapid Manufacture.

  • Sustainability

This process can be a project in itself and also tied into the carbon reduction process. Simplified we look to identify the lifecycle and durability with the product. This will tie into the product lifecycle influencing the pricing and product upgrade strategy.

  • Additional Value

During the optimisation process we work with the client to identify any Intellectual property (IP) opportunities and also ‘halo sales’ through the development of ‘bolt on’ products

In the current market environments the optimisation of products and equipment is the most cost effective way to remain competitive and sustain or improve profitability. In the development of new concepts the time invested in the initial design stages can be crucial to the success of the product. Also the tools available to Design engineers is increasing and improving dramatically as technology evolves, opening up new opportunities.



The team have provided solutions for UAV composite propellers, Joint Strike Fighter project, and reverse engineering projects, with our white light scanning service.

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