Automating the Design of an Entire Bracket Family: How Thales Alenia Space and CDS Accelerated 2x the Full Workflow
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Thales Alenia Space (TAS) is a leading European actor in space and defense, delivering advanced satellite systems, payloads, and orbital infrastructures for demanding institutional and commercial missions. TAS produces a wide range of antenna reflector tripods (brackets) every year to support diverse satellite payload configurations.
Although these parts share the same functional requirements and are subjected to identical load cases, their geometries differ slightly across programs, missions, and antenna architectures. In this project, TAS engineers must redesign 80+ tripod variants, each following a full CAD–simulation–manufacturability workflow. Their main objective was to automate low-value CAD tasks while exploring new possibilities of optimization for structural performance of every variants.
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Results achieved
50% lead time reduction
Using one single parametric workflow, TAS and CDS teams achieved a 50% reduction in the total lead time required to design the entire antenna reflector tripod family.
45% lighter tripods
Relative to the legacy tripod designs, TAS achieved an average mass reduction of 45% per part.
2 days per bracket
After identifying the most promising iteration, TAS and CDS were able to design each tripod variant in 2 days instead of the initial 2 weeks.
Following the project, our next step is to determine how Cognitive Design can be integrated into our design and engineering toolchain. Based on the work carried out with CDS, the results are highly promising and indicate a meaningful evolution in the way we approach engineering at Thales Alenia Space.
- Florent Lebrun, Technology and Innovation Lead at Thales Alenia Space
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FAQs
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Yes, some functions in Cognitive Design by CDS use AI (costing, conversion to CAD, manufacturing analysis). It is pre-trained by CDS and packaged in the software, so there is no training happening on your side, and your data is not used.
Yes, you can convert mesh or implicit models to CAD and export them as a .step. It works best for midly complex models (e.g. generative design results). Complexe models (integrating lattice structures for instance) can also be converted to CAD, but would take more time..
No, our workflows use hybrid meshing, keeping the original CAD precision around functional regions, and having smooth mesh elements on organic features.
Cognitive Design by CDS uses a proprietary hybrid geometrical engine, mainly based on implicit modeling (Signed Distance functions), with in addition mesh and CAD operators.
Cognitive Design by CDS uses a node-locked license system, tied to each workstation. This approach aligns with the offline, on-premise setup. Floating licenses are not yet available.
Cognitive Design by CDS is particularly well suited for complex, high-value mechanical parts such as lightweight structures, gearbox housings, functional brackets, or fixtures subjected to multiphysics loads. It is optimized for use cases in aerospace, defense, space, and advanced mobility systems.
Cognitive Design by CDS is an advanced concurrent plaftorm for design optimization that enhances component performance. It incorporates production constraints directly into the design phase, ensuring efficiency. This allows design engineers to streamline workflows and reduce development time.
Cognitive Design by CDS is tailored for engineers in large and medium-sized industrial companies. It is particularly beneficial for sectors like aerospace, automotive, defense, and space. The software addresses unique engineering challenges faced in these industries.
Cognitive Design by CDS uses an implicit modeling engine and parametric design to generate and optimize designs rapidly. By factoring in manufacturing constraints, it ensures that designs are feasible and efficient. This process minimizes the risk of failure during production.
Cognitive Design by CDS significantly reduces development time and enhances agility in the design process. It allows for quick iterations and optimizations, keeping your projects on track. By integrating manufacturing constraints early, it helps maintain competitiveness.
While Cognitive Design by CDS is user-friendly, we offer comprehensive training to maximize its potential. Our support team is available to assist with onboarding and any questions. This ensures that users can leverage the software effectively.
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