M-ARM: An automated systematic approach for generating new variant design options from an existing product family

Abstract Companies with established product families can meet emerging market needs by extending their product families over time, that is, by introducing new product variants sequentially. Starting points for each new design can be generated by integrating design solutions from existing products in the same family. This article introduces an automated systematic approach to derive all possible ways of combining existing designs to produce a new variant with a desired new combination of functionality, based on algorithmic analysis of product models. The approach considers the functions in existing products and how they are realised in specific CAD parts and the geometric features defining them. By automatically generating and evaluating all the options, the new approach helps identify the most efficient way to combine existing parts and features from a product family to generate a new product variant with distinct functionality. The approach has been applied to product families of mechanical and mechatronic consumer products. It was evaluated by manually implementing the automatically-generated redesign instructions in CAD for several product variants, which built confidence in the approach’s accuracy and performance. From the evaluation, opportunities for further work are suggested.