Design Process Evolution

by Brian Leadingham

CAD (Computer-Aided Design) has come an incredible distance since I started in mechanical design. As an engineering student, we studied both traditional drafting techniques on a board as well as learned the fundamentals of early CAD design tools. One of my first big design projects was designing a new engine block for the 3-Cylinder 75/90hp Evinrude ETEC engine. It was the early 2000s, and this was the first engine block that truly leveraged the CAD model to cut molds directly using CNC machining. What is now commonplace was revolutionary only two decades ago, representing a fundamental shift in how products were realized.

And just as the drafting board was replaced by complex parametric modeling software, that software is now evolving to the point where seamless simulations can be performed in virtually real-time. What used to be a digital drafting board has evolved into an integrated suite of software that drives intelligent engineering and design.

Today, the most effective teams aren’t using CAD just to model shapes—they’re embracing simulation-first design, developing simulation protocols in parallel to predict performance, validate ideas, and reduce risk long before the first physical prototype is ever made. This represents one of the biggest upgrades in our industry, and it's still accelerating.

Here’s what this shift has changed in my career:

Integrated Simulation

Modern CAD evolution means models can be directly imported into FEA (Finite Element Analysis) software, enabling fast assessment of motion analysis, mechanical and thermal loading, and exploration of design limits. Engineers get answers in days or even minutes, not months or weeks.

Design Control

Modern parametric modeling tools let teams iterate rapidly without losing track of the design intent. Every change is tracked, allowing for efficient rollback and transparent exploration of different design paths, which is critical for design validation.

Manufacturing Awareness

The inclusion of built-in Design for Manufacturing (DFM) checks prevents unmanufacturable ideas from slipping through the pipeline. This awareness saves immense time and cost by flagging potential production issues early.

Smarter Decision-Making

Designs backed by simulation data lead to fewer late-stage changes, fewer surprises, and higher-quality products. Design optimization and a deeper understanding of complex interactions lead to better design decisions and superior products hitting the market.

The shift from "draw first, test later" to "simulate early, iterate smart" is the foundational change driving modern engineering success.

Ready to Upgrade Your Workflow?

How has simulation changed your CAD workflow? Contact Design Department today to integrate simulation-first design and maximize your design validation success.