SYSTEM DESIGN

Calpak USA's mechanical engineering team uses SolidWorks for detailed solid modeling, assembly design, and drawing generation, along with CATIA for complex surface modeling and large-assembly management required by aerospace and defense programs. Our engineers leverage SolidWorks Simulation for linear static and thermal analysis, SolidWorks Flow Simulation for internal and external airflow studies, and SolidWorks PDM for version-controlled design data management across multi-engineer projects. For programs requiring CATIA compatibility, Calpak USA maintains full associativity with customer-furnished CATIA models to ensure seamless data exchange. All CAD environments at our Hawthorne, California facility are integrated with our schematic capture and PCB layout tools through STEP and IDF file exchanges, enabling mechanical engineers to import accurate board outlines, component heights, and connector locations directly into enclosure and chassis assemblies for precise electromechanical fit verification.

Calpak USA performs computational fluid dynamics and finite element thermal analysis early in the system design phase to map heat dissipation paths and identify thermal bottlenecks before physical prototypes are built. Our engineers design thermal management solutions including custom extruded and machined aluminum heat sinks, heat pipe assemblies, forced-air cooling with fan curve matching, liquid cold plate interfaces, and thermally conductive gap pads and interface materials. Calpak USA models component junction temperatures under worst-case operating conditions using manufacturer-published thermal resistance data and validated boundary conditions. For sealed enclosures that cannot use forced convection, our team designs conduction-cooled architectures with optimized fin geometry and chassis contact surfaces. All thermal designs developed at our Hawthorne, California facility are validated against AS9100 documentation requirements with thermal test reports comparing simulated predictions to measured prototype temperatures under representative power loading.

Calpak USA routinely designs mechanical systems around customer-furnished PCBAs, cable assemblies, and electronic subsystems. Our engineers import your board data via STEP, IDF, or ODB++ formats to create accurate 3D models that account for component keep-out zones, connector mating heights, cable bend radii, and airflow clearances. Calpak USA coordinates directly with your electronics team on mounting hole patterns, standoff heights, thermal interface requirements, EMI shielding provisions, and grounding strategies. When modification to existing electronics would improve the overall system, our in-house PCB design team can propose targeted board layout changes that enhance mechanical integration without requiring a full electrical redesign. All integration work at our Hawthorne, California facility follows formal interface control document processes under our AS9100 quality system to ensure mechanical and electronic design changes are tracked and coordinated across disciplines.

Calpak USA integrates Design for Manufacturability analysis throughout every mechanical design phase, starting from concept selection through detailed drawing release. Our engineers apply DFM principles specific to each target process including CNC machining, sheet metal fabrication, injection molding, die casting, and additive manufacturing. Calpak USA evaluates wall thicknesses, draft angles, undercut features, tolerance stackups using GD&T per ASME Y14.5, and surface finish callouts relative to functional and cosmetic requirements. We minimize unique fastener types, design self-locating features to reduce fixturing complexity, and specify standard commercial hardware wherever possible. For injection-molded parts, Calpak USA performs mold flow analysis to predict fill patterns, weld lines, and sink marks before tool commitments. Our Hawthorne, California facility maintains relationships with vetted domestic and international fabrication partners, and our engineers optimize designs for specific vendor capabilities to reduce cost and lead time.

Calpak USA performs finite element analysis for structural, thermal, and vibration loading using SolidWorks Simulation and ANSYS Mechanical to validate designs before prototyping and production tooling commitments. Our structural analyses cover linear static stress and deflection under operational loads, modal frequency extraction to avoid resonance with known excitation sources, random vibration power spectral density analysis per MIL-STD-810 and ASTM standards, and fatigue life prediction for cyclic loading applications. Calpak USA engineers build accurate material models using tested property data for metals, plastics, and composites, apply realistic boundary conditions derived from system-level interface loads, and converge mesh refinement studies to ensure result accuracy. All FEA reports generated at our Hawthorne, California facility include model descriptions, loading assumptions, mesh convergence evidence, safety margin summaries, and design recommendations traceable to your project requirements under our AS9100 quality system.