A Generalized Framework for CAD Design Automation of Configurable Products Through CAD–PLM Integration with Quantitative Industrial Validation

This study addresses the growing demand for efficient customization in industrial design by proposing a structured approach to automate Computer Aided Design (CAD) assembly generation and documentation. The objective is to reduce repetitive engineering effort while maintaining consistency and integration within existing digital environments. The methodology combines parametric modelling, configuration-driven design, and Visual Basic for Applications (VBA)-based scripting through CAD Application Programming Interfaces, supported by integration with a Product Lifecycle Management system. A structured data model and reorganised modular CAD architecture enable automated generation of assemblies, selection of configurations, and creation of technical drawings. The approach is validated through an industrial case study involving configurable mechanical assemblies, where performance is evaluated using a quantitative time-based framework. The results show a reduction in total configuration time from 8 to 16 h to approximately 2–3 h, corresponding to an average time saving of 79% and a significant decrease in effective engineering workload. Assessment of scalability indicates that engineering effort becomes largely independent of the number of configurations, while economic evaluation indicates strong return-on-investment potential under typical industrial conditions. The findings confirm that systematic CAD automation can substantially improve productivity and consistency in configuration-driven design processes, provided that parametric models and data structures are properly standardised.