Why Design Engineers Must Account for Compressed Air in Product Development

Suppose your manufacturing company is weeks away from unveiling a flawless automated assembly system. Just before you launch it, its performance falters under full capacity. Your team frantically tries to resolve the robotics and coding issues, only to discover that the real problem is with the compressed air system. In a worst-case scenario, you may need to delay the launch for a complete redesign that incorporates compressed air as a core component of your plans. 

It is not uncommon to overlook the importance of compressed air, especially in manufacturing environments. Yet centering pneumatics in the initial engineering stages can transform production.

Integrating Compressed Air Systems from Day One

Although design engineers have long viewed compressed air as a versatile utility, it is a trustworthy, powerful energy source that is highly underutilized in manufacturing and engineering. Compressed air is counterproductive across most industrial settings, losing more than 80% of its energy supply as heat.

The high energy consumption of this inefficiency is a significant cost factor in manufacturing, driven by leaks, poor piping configurations, various component issues and excessive pressure. Often, this leads to wasted electricity, more frequent maintenance needs, higher operating costs and a shorter equipment lifespan.

To remain competitive in today’s advanced manufacturing sector, industries must incorporate pneumatic systems into their planning stage from the outset. Doing so will allow companies to create more functional, dependable and ingenious products.

The Importance of Compressed Air—A Paradigm Shift in Design Engineering

The true importance of compressed air lies in engineering it as an integrated system that is vital for maximum performance. Essentially, engineers must treat it as a critical design parameter, rather than including it as a post-design utility.

For instance, when retrofitting industrial sites, compressed air can power the pneumatic controllers instead of natural gas, eliminating methane gas emissions. In this approach, atmospheric air is compressed, stored and dried before being channeled through the piping system.

Manufacturers must invest in some new equipment for this, but many parts are reusable. Overall, this forward-thinking approach enables significant savings, upgrades systems for greater reliability and efficiency and allows plants to achieve sustainability.

What is Compressed Air Used for in Manufacturing?

The use of compressed air in manufacturing is much more sophisticated than most people realize. For example, sanitary environments—such as those in the food and beverage, pharmaceutical or electronics industries—benefit the most from oil-free air compressors. Oil-free compressed air powers machinery and packaging systems without introducing oil and other contaminants and maintains product quality.

READ MORE: Digital Solution Precisely Monitors Compressed-Air Flow in Real Time

It is also applicable to robotics and precision automation, delivering the speed and power required to lift and place objects and even handle sensitive components. The manufacturing sector was among the first to embrace robotics, which—with the integration of artificial intelligence and the Internet of Things—could fully automate plant operations by the 2030s.

Additionally, air caster systems use compressed air to glide heavy and delicate machinery with little friction. This allows for easier, safer and more exact movement of objects within the manufacturing, logistics and construction industries. It also decreases the potential for damage to equipment and the facility. As the air caster market expands at an 8.4% compound annual growth rate between 2024 and 2031, further technological developments are improving its load capability, control, accuracy and adaptability for various applications.

Designing for Safety and Compliance in Pneumatic Systems

According to the Compressed Air & Gas Institute, pneumatics is typically a safe power source. It does not release harmful discharges into the atmosphere, its leaks do not pose a danger, and it is safe for use in wet, flammable or explosive environments. The devices themselves tend to be lighter and remain much cooler to the touch compared to similarly powered tools.

However, its integration into product design requires strict adherence to safety and compliance standards. From an engineering standpoint, you must follow requirements set by the Occupational Safety and Health Administration (OSHA) and the ANSI/CAGI B19.1 safety standard to avoid system failures and enhance user protection.

Proper safety transcends mere compliance adherence. Real-time sensor monitoring provides critical insights into air consumption, enabling you to regulate supply pressures and detect system leaks. The data-driven approach will help prevent equipment downtime by identifying potential technical issues and reducing costs, allowing you to maintain the highest level of safety for your machinery and its operators.

Analyzing the True Cost and Efficiency of Compressed Air

Pneumatics represent one of the most substantial operating expenses in manufacturing environments, underscoring the importance of compressed air efficiency. A facility's energy consumption can account for up to 80% of the total life cycle cost of this type of system. Even a marginal increase in working pressure requires an 8% increase in electricity consumption. This cost does not include the costs of investment, maintenance and operations, which result in additional financial constraints.

Smart engineering is necessary to address nominal design defects—including poorly sized parts and bends in the tubing—to reduce energy waste. Approaching pneumatic designs with a more holistic view and a closer examination of long-term expenses can convert a significant expenditure into a value driver.

Leveraging Digital Twins and Simulation to Model Airflow

Whereas engineers once relied on a build-and-test approach to prototyping pneumatic systems, a new era of advanced simulation software and digital twin technology has enabled more predictive design processes. With digital twins, you can create a virtual replica of your compressed air equipment, accurately modeling the complex behaviors of the finished product.

The technology allows you to identify and correct problems early in the design stages, saving your time, resources and money should the system inefficiencies cause it to fail later. Mastering these simulation tools in the future will be essential to ensuring your pneumatic system designs are suitable for various applications from the start.

The Next Generation of Pneumatic Design Engineering

Future designs of compressed air systems lean into innovative, efficient and fullyintegrated mechanics. Engineers utilize the latest technology to develop high-performance equipment that delivers insights for optimization and creates more responsive, powerful products. It is time to treat compressed air as more than a utility and embrace it as a groundbreaking industry opportunity.