Integrated DFMA, Sustainability, and Finite Element Assessment of a Vacuum Thermos Flask Redesign

M. F. Rosli; M. S. M. Effendi; M. L. Abd Latif; M. K. Asmawi; Suhaimi Shahrin

doi:10.58915/aset.v5i2.3537

Authors

M. F. Rosli Universiti Malaysia Perlis
M. S. M. Effendi Universiti Malaysia Perlis
M. L. Abd Latif Universiti Malaysia Perlis
M. K. Asmawi Universiti Malaysia Perlis
Suhaimi Shahrin Universiti Malaysia Perlis

DOI:

https://doi.org/10.58915/aset.v5i2.3537

Keywords:

Design for manufacturing and assembly, Finite element analysis, Product redesign, Sustainable design, Vacuum thermos flask

Abstract

This study evaluates a redesigned vacuum thermos flask by integrating Design for Manufacturing and Assembly (DFMA), computer-aided sustainability assessment, finite element analysis (FEA), and cost comparison. The baseline and redesigned models were developed in SolidWorks 2019. The redesign increased the reported part count from 2 to 6 and assembly time from 120.25 to 360.48 s, while assembly cost rose from RM1.30 to RM2.80; however, the reported design-efficiency score increased from 30% to 48%. Replacing the principal AISI 304 body material with high-density polyethylene reduced modelled product mass from 1107.81 to 149.69 g. The software outputs indicated reductions of 88.78% in carbon footprint, 99.59% in water eutrophication, 83.30% in air acidification, and 87.14% in total energy consumption. Injection-moulded component cost decreased by 30.76%. FEA results under a 100 N load were mixed: most cases remained below the reported yield strength, but one stress result and one displacement result were physically inconsistent and require model verification. The redesign therefore offers substantial environmental and material benefits but introduces assembly and structural-validation trade-offs. The study supports Sustainable Development Goals 9 and 12 through resource-efficient product development and digital engineering.

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