Product Design




Structural Durability/Fracture
Wayne Gregg – NASA/MSFC – Huntsville, AL

“Mr. Dambaugh supported the Damage Tolerance Team work efforts for NASA’s Constellation Program Upper Stage design and development efforts.  He provided leadership in developing and executing assessment plans for various design issues.  His development plans were thorough yet concise, without requiring an excessive set of analytic evaluations.  His ability to formulate these plans quickly while coordinating customer needs was exemplary.”


Structural Durability/Fracture
Brian Callahan, Ph.D. – XRD, Inc. – Beaufort, SC

“Mr. Dambaugh of FEA SERVICES was a pleasure to work with, and he got the job done within budget and ahead of time. He was diligent, insightful, professional, timely, polite, and a good teacher.  Ours was an unintuitive, complex problem, but he handled it with ease.  The revised component survived the abuse, and helped our engine become the first and only heavy fuel solution in its class ever to pass the US Army’s endurance qualification test for unmanned airplanes.”


Structural Durability/Fracture

“The people at Callies Performance Products would like to thank all those at FEA SERVICES who were involved with the evaluation and development of our recently implemented crankshaft modifications.  Your company’s support has greatly helped us in eliminating a long standing product weakness.  Recommended changes in both material and design appear to have solved the problem.  We appreciate the quick response and your attention to the details of our project.”


Structural Durability/Fracture
Wayne Bouldin – MEMBRANA – Charlotte, NC

“Your material analysis through FEA has proven very beneficial to a project of mine where we incorporated a common polymeric material into a new application using a non-standard forming process. The analysis results served well to reassure customers of the product robustness and safety.  Sales of this product have contributed significantly to record company sales throughout last year.  The investment in your services has paid for itself many times over.”


Structural Durability/Fracture
Charles Runkle, Ph.D. – CELGARD – Charlotte, NC

“In late 2002 we were developing a new 14in product for a broader industrial ultra-pure water market.  I was using a thermoplastic containment vessel design.  The 14in tubular vessel itself is a thermos-formed PVC pipe, and in early prototypes we had some serious durability concerns about the PVC end caps, and chose to develop a cast nylon end cap for the production design.  With the considerable help from Gabe Dambaugh, we completed that design with extensive FEA of the stress profiles in the end cap geometry, and are confident that structural durability and strength are much improved by using the cast nylon approach.”