Mallett Technology, Inc.

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Structural FEA Consulting

For 33 years, Mallett Technology has provided our customers with solutions to their most challenging Finite Element Analysis (FEA) simulation problems. Our state-of-the-art computing cluster paired with the full suite of Ansys® FEA tools enables us to tackle any type of problem, no matter the scale or complexity.

We have extensive experience with all facets of structural FEA including:

  • Static Stress Analysis
  • Vibration Analysis
    • Modal
    • Random Vibration / Power Spectral Density (PSD)
    • Harmonic Vibration / Sinusoidal
    • Seismic Analysis / Response Spectrum
    • Vibration isolation evaluation
  • Transient Analysis
  • Shock Analysis
  • Non-linear Contact / Frictional sliding
  • Large deformations and buckling
  • Plasticity, hyperelasticity, viscoelasticity
  • Thermal Strain
  • Fatigue Analysis
    • High cycle fatigue
    • Low cycle fatigue
    • Vibration-induced fatigue
    • Thermal fatigue
    • Weld fatigue
    • Bolt fatigue
  • Fracture mechanics and crack propagation
  • Detailed Weld Evaluation (AWS and Eurocode)
  • Polymers, Elastomers, composites, foams, exotic alloys, etc.
  • Temperature and rate dependencies
  • Fastener evaluation
  • Creep Analysis

Time and time again, correlation with physical testing and instrumentation has proven our ability to accurately and efficiently capture even the most complicated system behavior. We have experience with nearly every industry and the associated standards, and we are confident we can meet your needs and exceed your expectations. Contact us today to discuss your project.

Example Projects

Below are some examples of our analysis projects. These examples have been generalized to protect our clients, and this list is by no means exhaustive. If you don’t see anything representative of what you want to analyze, please contact us and we can provide examples of some of our projects that are similar to your needs.

Military Aircraft Subsystem

Will the module withstand an extreme environments (shock, random vibration, acoustics)?

  • MIL-STD-810 shock and vibration loading
  • Acoustic loading originating from the engine pod
  • Structural fatigue evaluation
  • Collaboration with Raytheon to implement acoustic analysis methodology

Design acceptance for use in the Ram Air Turbine Generator (RATG) subsystem for the Next Generation Jammer (NGJ) Aeromechanical (AM) Pods.

Hyperelastic Membrane – Sealed Container

Can the membrane survive extreme stretching and how much force does it transmit to the frame?

  • Hyperelastic membrane
  • Mooney-Rivlin, Ogden, Yeoh… formulations available for modeling elastomeric materials
  • Extreme deformations
  • Frictional sliding contact

Simulation correlated very well to experiment. Optimized membrane thickness and frame structure.

Railcar Lavatory System

Will the module survive 20+ years of service per IEC 61373?

  • Modal Analysis (natural vibration frequencies)
  • Random vibration simulation track conditions
  • Shock and static overload cases simulating car coupling
  • Large system-level detailed model
  • Fiber-Reinforced Plastic (FRP) panels
  • Detailed fatigue evaluations

Optimized the fiberglass structure for robust, long-life performance.

Aluminum Extrusion Press

Will the extrusion press survive decades of service under tremendous, cyclic pressurization?

  • Detailed fatigue analysis of tie rods, main cylinder, supports
  • Detailed weld fatigue evaluation per AWS D1.1
  • Cyclic pressurization superposed on gravitational loads
  • Mallett’s results reviewed and accepted by independent 3rd party

Qualified the design per contract requirements; customer obtained approval to proceed with fabrication and delivery.

Large Pillow Tank – Military, Desert Fuel Storage

Will the tank perform robustly (pressurization, military application)?

  • Transient solution simulates tank inflation from empty to full capacity (diesel fuel).
  • Ground interaction (sand or packed earth) and tank wrinkling are captured and accounted for
  • Orthotropic fabric with various seams and reinforcements
  • Optimize tank footprint versus volume

Tank safety factors meet or exceed all requirements for all load cases.

Precision Bearings

What are the bearing loads, clearances, and stresses over a range of temperatures and speeds?

  • Combined thermal analysis and structural analysis
  • Minute clearance changes due to temperature and varying mechanical loads
  • Accurate characterization of heat loads due to friction
  • Accounted for initial shrink fit and bearing preload
  • Accounted for individual rolling elements

Precisely determined the initial clearance required for robust operation over a range of temperatures and speeds.

User-defined Creep Law

Will the bogie assembly suffer long-term sag or warp?

  • Ansys customization via Fortran subroutine
  • Specialized long-term creep behavior
  • Commercial rail transportation
  • Customer uses Ansys; Mallett extended capability

Delivered custom Ansys executable for creep simulation

Articulating Cleaning Product

Will the product withstand abusive use?

  • Frictional contact between a large number of parts
  • Large range of motion (articulation)
  • Injection-molded plastic and steel interaction
  • High volume consumer product

Identified a critical design flaw ahead of prototyping

Nuclear Power Pressure Vessel, Filter Assembly

Does the pressure vessel meet stated nuclear industry requirements?

  • Bolt pretension, gasket compression, sealing analysis
  • Self-weight and support bracket evaluation
  • Fatigue evaluation due to cyclic pressurization
  • ASME Boiler & Pressure Vessel Compliance (B&PV)
  • Specialty gasket material and steel alloy

Qualified the assembly for usage in Nuclear Power Generation

Fluid Filled Tank

Will the tank survive 20+ years of service per IEC 61373?

  • Sloshing fluid in double walled tank
  • Fluid-structure interaction
  • Weld stress and fatigue analysis per AWS D1.1
  • Plastic deformation
  • Random vibration and transient shock

Identified failure areas and helped redesign the product. Product passed testing after redesign.

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Mallett Technology, Inc.

Mallett Technology, Inc.
4601 Creekstone Drive
Suite 120
Durham, NC 27703

Phone: (800) 832-3767
Fax: (919) 474-9223

About Mallett Technology

Mallett Technology, Inc combines our broad knowledge and expertise with best-in-class engineering software tools to help our clients compete in today's marketplace and produce reliable and cost-effective products.

Mallett is an ITAR Registered Company

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