More than 40% cost reduction through drop test simulation with Ansys LS-DYNA

The cost-sensitive development project for a new sewing machine series within Bernina International AG includes optimizing the packaging to the new logistical conditions and adapting it to the new product design. Packaging protection also had to be increased. Regarding specifications, no acceleration forces more significant than 100G may occur on the machine during a standardized drop test from a height of 0.9m. Furthermore, polystyrene should be reduced by at least 20% for cost and environmental reasons. For the end customer, the package should be easy to transport by hand and leave a tidy and logical impression when unpacked, which was difficult to specify and led to some loose ends concerning the arrangement of accessories.