As the section was quite complicated, our consultants
did a quick parameter study using a box section, to find
appropriate section properties to give acceptable deflections.
Our consultants then designed a new extrusion with these
properties, built a new FEA model
and predicted its performance. The new design controlled
the deflections and twisting and also reduced the peak
Our consultants also gave our customer the option of
using a steel box section inside a cosmetic cover, which
would have looked the same as the original design externally,
but with significant cost savings.