PROTOTYPING

Do WE Need Prototype
 To produce an article that will serve the purpose of use
without making modifications to the original shape or
general design.
 Discussion piece.
 Design and fit.
 Assembly capabilities.
 Suitability of mechanical properties.
 Manufacturing process capabilities (forging, casting,
pressing, fabrication etc.)
Four Uses of Prototypes
 Learning
 answering questions about performance or feasibility
 e.g., proof-of-concept model
 Communication
 demonstration of product for feedback
 e.g., 3D physical models of style or function
 Integration
 combination of sub-systems into system model
 e.g., alpha or beta test models
 Milestones
 goal for development team’s schedule
 e.g., first testable hardware
Types of Prototypes Physical

ball alpha beta

support prototype prototype
final
prototype product

trackball mechanism
linked to circuit
Focused simulation Comprehensive

simulation
of trackball
circuits not
generally
feasible

equations
modeling ball
supports Analytical
Physical vs. Analytical Prototypes
Physical Prototypes
 Tangible approximation of the
product.
 May exhibit unmodeled
behavior.
 Some behavior may be an
artifact of the approximation.
 Often best for
communication.
Analytical Prototypes
 Mathematical model of the
product.
 Can only exhibit behavior
arising from explicitly modeled
phenomena. (However,
behavior is not always
anticipated.
 Some behavior may be an
artifact of the analytical
method.
 Often allow more experimental
freedom than physical models.
Focused vs. Comprehensive Prototypes

Focused Prototypes Comprehensive Prototypes

 Implement one or a few  Implement many or all
attributes of the attributes of the product.
product.  Offer opportunities for
 Answer specific rigorous testing.
questions about the  Often best for milestones
product design. and integration.
 Generally several are
required.
Boeing 777 Testing
Brakes Test
 Minimum rotor thickness
 Maximum takeoff weight
 Maximum runway speed
 Will the brakes ignite?
Wing Test
 Maximum loading
 When will it break?
 Where will it break?
 Comprehensive Prototypes
Many comprehensive Some comprehensive
prototypes are built. prototypes build (and sold?).
High
Technical or Market Risk

One prototype may be Few or no comprehensive

used for verification. prototypes are built.
Low

Low High
Cost of Comprehensive Prototype
Prototyping Strategy
 Use prototypes to reduce uncertainty.
 Make models with a defined purpose.
 Consider multiple forms of prototypes.
 Choose the timing of prototype cycles.
 Many early models are used to validate concepts.
 Relatively few comprehensive models are necessary
to test integration.
 Plan time to learn from prototype cycles.
 Avoid the “hardware swamp”.
Traditional Prototyping Methods
 CNC machining
 Rubber molding + urethane casting

 Materials: wood, foam, plastics, etc.

 Model making requires special skills.
Virtual Prototyping
 3D CAD models enable many kinds of analysis:
 Fit and assembly
 Manufacturability
 Form and style
 Kinematics
 Finite element analysis (stress, thermal)
 Crash testing
 more every year...
BMW Virtual Crash Test

From: Scientific American, March 1999

RAPID PROTOTYPING
 The Definition of a Prototype according to the
Oxford Dictionary

”The original thing or person in relation to any copy,

imitation, representation, later specimen or
improved form”.
RAPID PROTOTYPING
` The term "rapid prototyping" is a relatively new expression
for the generation of three-dimensional models
manufactured without the need for machining or tooling.
` Rapid Prototyping is the ability to rapidly produce accurate,
tangible models of products designed on a computer aided
design system.
` Rapid Prototyping concentrates the mind on getting the
product Right First Time
RAPID PROTOTYPING
Product Life Cycle

DISPOSAL NEED

Product DESIGN
USAGE
Life Cycle DEVELOPMENT

DISTRIBUTION PRODUCTION
RAPID PROTOTYPING
Product Life Cycle in Sales History
Rapid Prototyping Methods
 Most of these methods are additive, rather than
subtractive processes.
 Build parts in layers based on CAD model.
 SLA=Stereolithogrpahy Apparatus
 SLS=Selective Laser Sintering
 3D Printing
 LOM=Laminated Object Manufacturing
 Others every year...
RAPID PROTOTYPING
Limitations on Production of models by machining :-

 Material removed during forming is difficult to reclaim.

 Machining, in the form of drilling, turning, milling, spark
erosion etc., is limited by the shapes it can produce.
 In the event of design change conventional tooling such as
patterns, core boxes, dies, jigs etc., become expensive to alter
and, in many cases, may require complete re-manufacture.
RAPID PROTOTYPING
Advantage of Rapid Prototyping Process
 Adding material layer by layer until the desired shape is
achieved, immediately reducing or avoiding the loss of
material.
 Cutting out the conventional draftsperson, patternmaker
and in some situations even the moulder, the system goes a
long way towards reducing time taken and cost and
improving accuracy.
RAPID PROTOTYPING
 RP machines process CAD data by slicing the computer model
into layers, each layer being typically 0.1 - 0.25mm thick.
 The machine then uses this data to construct the model layer by
layer, each layer being bonded to the previous until a solid object
is formed.
 Due to this laminated method of construction a stepped surface is
developed on curved faces, the removal of which is essential if
maximum advantage of the process is to be realised
Schematic representation of the stepped construction which
requires post processing
RAPID PROTOTYPING
The Benefits
 Converts 3D CAD images into accurate physical models
at a fraction of the cost of traditional methods
 Improves design communication and helps eliminate
design mistakes
 Reduces 'Time to Market' for a new product
 Can be used as a powerful marketing tool since the
prototype can be seen rather than the drawing
RAPID PROTOTYPING

The Case for Rapid Prototyping

 Visual Models
 Getting to Market Sooner
 Increasing Sales .
 Generating Customer Goodwill through Improved
Quality
 Expanding Product Range.
 Reducing the Cost and Fear of Failure
The Case for Rapid Prototyping
Visual Models
 Consumer product manufacturers find value in having tangible models
of their proposed products to show to customers.
 IBM used SLA to produce operating display units of its ThinkPad tablet
computer for the annual COMDEX show.
 Key Tronics, who manufacture computer keyboards, create physical parts
for customer approval.
 Logitech, the worlds largest manufacturer of pointing devices, was
asked, by a "blue chip computer company" to quote on a unique two-
button mouse; in less than two weeks from the initial request Logitech’s
team returned with a functional SLA prototype. The customer’s reaction
was one of ‘disbelief '. Part quality was so superior that the computer
giant awarded the contract on the spot. It is thought that this single
order paid for the SLA system.
 Coca-Cola used RP to design the nostalgic (coke bottle) curves into a
contemporary 20 ounce plastic Coke bottle.
The Case for Rapid Prototyping
Increasing Sales by:
 Producing visual models for market research, publicity, packaging etc.,
 Getting to market sooner.
 Generating customer goodwill through improved quality.
 Expanding the product range.
 Reducing the cost and fear of failure.
The Case for Rapid Prototyping
Getting to Market Sooner
 The phrase "Time to Market" is first thought to have been used in a classic 1983
article by McKinsey & Co on product development that stated: "Six months of
delay can reduce a product’s life cycle profits by 33%".
 "The first product to market has a 100% share of that market in the beginning. The
earlier a product appears, the better are its prospects for obtaining and retaining a
large share of the market…
 For each month cut from a product’s development cycle a month can be added to its
sales life, representing an extra month of revenue and profit…
 It gains more customer loyalty due to the cost of switching to another product…

 A third benefit is higher profit margins. If a new product appears before there is
competition, the company will enjoy more pricing freedom, making higher profit
margins…"
The Case for Rapid Prototyping
Generating Customer Goodwill through Improved Quality
 The end result has been less re-design, improved products and most
importantly, greater customer satisfaction. This has lead to many
companies in the USA producing a RP model with every quote.
The Case for Rapid Prototyping
Expanding Product Range
 Today’s market place is characterised by more frequent introductions of
more product variants each having a life cycle than the previous one. In
addition, lead-times demanded are shorter than ever before.
 Clearly, RP makes a positive contribution here, by compressing
development times, thus making it possible to respond to the demands
of the niche markets and to introduce new products more frequently.
The Case for Rapid Prototyping
Reducing the Cost and Fear of Failure
 It takes a very confident person to allocate / sanction large amounts of
money and resources on tooling for a product that might not make it on
the market. This will inevitably make people cautious and restrict their
design flair to those tried and tested shapes and systems. Where a
relatively cheap model can be produced quickly it reduces the fear that
traditional methods attract allowing the designer to be more
adventurous.
The Case for Rapid Prototyping
Reducing the Cost and Fear of Failure

CASE OF PORSCHE : Cylinder head prototype

 Conventional techniques : CAD & NC
 sand casting pattern + tooling: $74 000
 casting for 5 parts : $3500
 time : 16 weeks

 Rapid protityping : Selective Laser Sintering

 CAD works :$ 8000
 Wax parts using SLS : $15000
 casting 5 parts : $ 3500
 Time : 4 weeks
RAPID PROTOTYPING
5% Preliminary Design
Detail Design
25 %
Time Saving 50 %

50 %
Built & tests Process Preliminary Design 20 %

Detail Design 10 %
20 % Built & tests Process 15 %
Documentation 5%
Documentation
Sunstrand Electric Power System : current Transformer/Electromagnetic Interference
RAPID PROTOTYPING
Revenue (US$)

Revenue curve for d(3W-d)

on time market entry Revenue Loss =
2W2

Revenue curve for

delayed market entry

d
delay
Market window (w)
Produk life cycle (2W)
RAPID PROTOTYPING
Product Development Time VS Product lifetime

10

8 Average Product Lifetime

6
Years

4
Average Product
2 Development Time

0
1965 1970 1975 1980 1985 1990 1995
Years
RAPID PROTOTYPING

Requirements Rapid Prototyping

Specifications Performance Analysis

Design