General Industry/Automotive

Customized (Not Compromised) Solutions

Providing customized design solutions based on FlexSys' compliant system design paradigm.

Several studies have indicated that assembly accounts for about 40% of the labor cost and about 50% of the total cost to manufacture a product. One of the tenets of Design for Assembly (DFA) is to consolidate parts into an integrated design unless there is a functional reason for relative motion and/or material differences. An approach called Design for No Assembly (DNA) takes an even more radical view and advocates that compliant systems can be used to consolidate parts even when there is relative motion between them. This cuts manufacturing costs and at times eliminates the need for assembly altogether. Almost any product can be considered for a no-assembly design solution with FlexSys compliant design paradigm.

Windshield Wiper

An example of Design for No Assembly is the one-piece wiper blade developed by FlexSys. This novel structure evenly distributes pressure over the blade and conforms to any glass shape, from flat to highly curved. The one-piece whiffletree design meets stringent performance specifications required by OEMs, and costs less to manufacture than traditional metal and plastic snap-fit designs


Standard Wiper Parts and Single Piece FlexSys Wiper. Comparison of a multi-part conventional wiper with a single piece FlexSys Wiper. U.S. US Patents 6,301,742 B1, 7,360,272 and International patents issued.

Intelligent Design

In addition to compliant systems, FlexSys develops other types of custom electromechanical systems for the automotive, aerospace, medical, and other industries. Our staff has a great deal of creativity and expertise in elements of machine design (bearings, gearing, traditional mechanisms, motors, and the like), finite element analysis, and manufacturing, which allows us to efficiently design systems and assemblies to perform complex tasks.

Side View Mirror

FlexSys redesigned the mount and control mechanism for an automotive side view mirror to cut the number of parts in half and reduce the packed volume by 30%. Accomplishing this task required the use of project specific and traditional design tools.