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Mechanical Design Synthesis (MDS) is an evolutionary step in design methodology. It combines several past steps such as Design by Analysis, Finite Element Analysis, Dynamic Mechanism Modeling, Thermal Analysis, Parametric Sensitivity, and Shape Optimization techniques under one software design environment. MDS can benefit every phase of the product development and delivery process and all members of the extended design team. A definition of MDS and a differentiation of MDS versus traditional methods are followed by a case study where MDS was used to trim 25% of the cost from a proposed design. The redesign project, which started with a nearly clean sheet of paper, was completed in 20% of the calendar time with a fourth as many people involved as in the first design attempt.

The conceptualization, design, analysis, prototyping, and testing of a steel casting are described. The methods used include 2D CAD, 3D solid modeling, finite element analysis, Solid Ground Curing rapid prototyping, and laboratory prototype testing. The part was successfully delivered to field testing on time. The use of the MCAE techniques provided a more optimal part more quickly than the use of standard CAD techniques would have provided. A minor cost penalty was paid for the prototype pattern versus conventional prototyping.