Unit 3.4.

Computer Aided Design

Essential Idea:

A computer-aided design is the generation, creation, development and analysis of a design

or system using computer software.

Nature of design:

As technologies improve and the software becomes more powerful, so do the opportunities
for designers to create new and exciting products, services and systems. Greater freedom in
customization and personalization of products has a significant impact on the end user. The
ability to virtually prototype, visualize and share designs enhances the whole design cycle
from data analysis through to final designs.

Aim of the design:

The use of CAD to simulate the conditions in which a product will be used allows the
designer to gain valuable data at low cost. For example, simulating the flow of air across a
car exterior negates the need for a car and wind tunnel.

A simulation is a model that mimics the operation of an existing or proposed system,

providing evidence for decision-making by being able to test different scenarios or process
changes.

Concepts and principles:

 Types of CAD software
 Surface and solid models
 Data modelling including statistical modelling
 Virtual prototyping
 Bottom-up and top-down modelling
 Digital humans: motion capture, haptic technology, virtual reality (VR), and
animation
 Finite element analysis (FEA)

Guidance:
 Identify the advantages and disadvantages of using computer-aided modelling
 Understand how data models structure data through database models
 Understand that the design of information systems enable the exchange data
 Understand how haptic technology, motion capture, VR and animation can be used
to simulate design scenarios and contexts
 Be able to compare FEA testing strategies with physical models testing
 Understand how FEA systems are used when designing and developing products

Types of CAD software:

There is a variety of different types of CAD software depending on the application to which
it is being applied. Each of these systems applies is own form of internal logic that must be
understood by designers.

1
CAD software is used in various stages of the design process to create, modify, and evaluate
designs.

2-D Software 3-D Software Rendering Software

Software that produces a 2-D Software that creates a 3-D Software that creates a
image of a design. These model that contains realistic, but virtual
images are used to information about the representation of a design.
communicate about the dimensions, materials, etc.
This is used to present the
design. of the design. This
information can be used to design concept to clients and
produce the design using for advertising.
CAM.

 Autodesk Fusion 360

 Blender
 Adobe Illustrator  Autodesk Inventor  Maya
 Adobe Photoshop  Sketch Up
 3D Studio Max
 Solid works

Use Cases Use Cases Use Cases

 to create digital  Creation of parametric  presentation of design

drawings that can models that can be to clients
communicate concepts used by CAM  preparation of
and information to a equipment to produce advertising and
client; the final product; promotion materials
 Serve as a foundation  Present and explore
for refining a design; concepts before going
 Some 2D drawing file into production or
formats (DFX, for prototyping;
example) can be used  Calculate material
by CAD equipment such properties of a design
as laser cutters and using Finite Element
routers; Analysis (FEA).
 Presentation of
schematic drawings
such as circuits, floor
plans, etc.

2
Parametric models: 3D models that are defined by constraints and features. This type of
modelling allows for changes to be quickly and accurately made and updated automatically.
The kinds of models you build in Fusion 360 are parametric models

Figure 1: Product design presentation created in Adobe Illustrator

Figure 2: Fusion 360 workspace

3
 Figure 3: Rendering in MAYA

In 3-D graphic design, rendering is the process of add shading, colour and lamination to a
2-D or 3-D wireframe in order to create life-like images on a screen.

4
Use Cases (2-D software):
 to create digital drawings that can communicate concepts and information to a
client
 Serve as a foundation for refining a design
 Some 2D drawing file formats (DFX, for example) can be used to by CAD equipment
such as laser cutters and routers
 Presentation of schematic drawings such as circuits, floor plans, etc.

Use Cases (3-D software):

 Creation of parametric models that can be used by CAM equipment to produce the
final product
 Present and explore concepts before going into production or prototyping
 Calculate material properties of a design using Finite Element Analysis (FEA)

Use Cases (Rendering software):

 presentation of design to clients
 preparation of advertising and promotion materials

SURFACE MODELLING:

Surface modelling, sometimes called rendering, and only communicates information about
the surface of the design. Rendering software uses data about the surface qualities,
material, lighting, etc., to create a virtual representation of the product. There is no
information about the interior of the product, the parts, or components.

These types of models are usually presented as 2D graphics files (JPEG, PNG, TIFF, etc.) or
animated videos. Blender, Maya, and 3D Studio Max are examples of surface modelling
programs.

5
Purpose: To communicate the aesthetic form and scale of an object.

Audience: Clients who want to understand how a design will look. Designers who want to
quickly communicate ideas.

Figure 4: This image of a Dyson hair dryer is created as a 3D model. However, the data in the
file can only be used for 2d graphics, and animation. There is no information about the
internal components, materials, etc. The model does not contain information that another
machine (like a 3D printer) could use to produce the part.

SOLID MODELS:

They are accurate digital models of the whole part or object. They contain information that
can be used by CAM hardware to produce the part or object. Solid model file formats
include STL, commonly used for 3D printing.

Purpose: To communicate in great detail the dimensions, materials, components, function,

etc. of a design. To provide detail that can be used in the manufacture of the design using
CAD/CAM technologies

Audience: Designers and Manufacturers who need information about how to manufacture
the design using CAD/CAM technology.

6
Figure 5: This example of a drone contains information about the form and shape, but also
materials, dimensions, etc. The information in this CAD model could be used by other
machines (like a 3D printer, for example) to produce the product.

Advantages and disadvantages of CAD software:

Advantages:

1. Changes, iterations and modifications to ideas can quickly be made

2. Convenient communication between designer and clients, teams, and
manufacturers
3. Electronically stored and transferred files are safe, secure, and easily shared.
4. Modelling can reduce costs and risks by identifying errors before full scale
manufacturing
5. Reduced costs and waste as fewer physical prototypes need to be
manufactured
6. Time and resources can be saved through efficient work practices
7. High accuracy of design and product

Disadvantages:

1. Software can be expensive

2. Specialized training required can be time consuming and expensive

7
CAD Modelling Strategies: Top-Down, Bottom-up, or Hybrid:

Designers have several strategies by which they can approach developing a CAD model. It is
important to consider which strategy is best suited for the design goal.

Bottom-Up Strategies Top-Down Strategies

Design begins with detailed criteria Design begins with criteria and
and specifications parameters and is then developed as
concept
Individual parts are designed New features and parts are added as
separately and then assembled the design evolves
into the final design
FEATURES There is no relationship between Related parts are connected - if one
parts - if a dimension is changed, dimension is changed, associated
associated dimensions must be dimensions on other parts will also be
changed individually adjusted.
Components can be reused across The final design is a collection of inter-
multiple assemblies related parts that are uniquely design.
Detailed and precise parameters The design begins as a concept, with
and design specifications are some design specifications established.
established before the actual
designing takes place
Few or limited changes are Design is expected to evolve through
USE CASES anticipated numerous iterations - numerous
changes are expected
Large complex systems (buildings,
spacecraft, vehicles)
Designing products that are made Product design of unique consumer
from standard parts products

Hybrid / Middle Out:

A combination of both approaches. Some of the parts are designed individually (bottom up)
while others are designed using the relational Top-down approach. Most modern CAD
software allows a combination of both approaches.

DATA MODELS:

These types of models typically consist of a database or data set that is used to present and
or understand the performance for a design. Data modelling is based on the requirements
for the use of context or application.

Data models can be structured either as a flat, hierarchical or relational database.

8
(a) Flat file models:

 Use a file structure involving data records that have no structured relationship.

(b) Hierarchical models:

 Do not link records together like a family tree, but each record type has only one
owner. (eg: a purchase order is owned by only one owner)

(c) Relational models:

 Organise data as a set of formally described tables from which data can be accessed
or reassembled in many ways without having to reorganize the database tables.

9
(d) Object oriented models:

In object oriented data model, data and their relationships are contained in a single
structure which is referred as object in this data model. For example, real world problems
are represented as objects with different attributes.

- Objects:

An object is an abstraction of a real world entity or we can say it is an instance of class. An

object encapsulates data and code into a single unit which provide data abstraction by
hiding the implementation details from the user. For example: Instances of student, doctor,
engineer in above figure.

- Attributes:

An attribute describes the properties of object. For example: Object is STUDENT and its
attribute are Roll no, Branch, Set marks () in the student class.

10
(e) Network models:

 It is a special case of the hierarchical data model in which each record type can have
multiple owners ( eg: purchase orders are owned by both customers and products)

Using motion capture technology, accurate data can be gathered to understand the
performance and design context.

Finite Element Analysis (FEA):

Finite Element Analysis (FEA) is the calculation of loads and stresses on a product using CAD
software. FEA uses a computer model of an object that is then analysed to how it reacts
when certain stresses such as heat, force, or load are applied.

Stress: It is the force acting on a unit area.

FEA is a powerful tool that allows a designer to virtually evaluate the suitability, durability,
and strength of design before producing a costly physical prototype.

Two common forms of FEA that a product designer might perform are:

 Fatigue: to analyse the durability of a product. To determine where cracks might

propagate in the design

 Heat: to analyse how heat is transferred through the product. To determine where
hot spots might be in a design and if these may degrade the design

11
 Figure 6: FEA analysis of the bicycle frame above shows areas of great stress (Red), and low stress
(Blue)

Figure 7: Visualization of how a car deforms in an asymmetrical crash using finite element analysis

VIRTUAL PROTOTYPING:

Prototyping is the use of CAD to develop realistic, interactive models. These virtual models
allow the designer to simulate the design, communicate with clients and the design team,
and explore the design. Virtual prototyping is powerful tool because it can:

 reduce development costs by identifying errors without the need to produce

physical prototypes

 improve quality of the final product as performance characteristics can be analysed

and confirmed before production

 reduce development time as designs can quickly be created and modified based on
feedback from the client, engineers, etc.

Virtual prototyping can involve various aspects of CAD, from Solid or Surface models, FEM,
to video fly-through.

12
 DIGITAL HUMANS, MOTION CAPTURE, HAPTIC TECHNOLOGY,

VIRTUAL REALITY (VR), AND ANIMATION

DIGITAL HUMANS:

Digital humans are digital simulations of the biomechanics of the human body. These kinds
of models are used to predict how humans will move and interact with a virtual prototype.

Source and watch the video on https://www.youtube.com/watch?v=OWnYlWCATmI

[The video link above shows how digital humans are used to design the cockpit (interior) of cars, as well as the
manufacturing assembly line]

Watch the video on https://www.youtube.com/watch?v=Hpk-NKTVbMk

[The video link above shows Pascal Berard speaking about the Digital Human Project to be used by film
makers]

13
Using digital models of human’s designers can analyse and confirm:

Safety and Comfort:

 Ensure there is enough space to perform a maintenance task (i.e. Is it possible to

remove a part by hand and replace it?)
 Ensure that controls are accessible and adjustable (Can the dashboard controls of
the car be reached by a seated and belted passenger?)
 Ensure that tasks do not require excessive force to perform by hand (Can a handle be
turned comfortably?)

Efficiency:

 Ensure equipment, controls, and machines are positioned to save time and avoid
hazards

Resources: Download Digital Human models from the Open Design Lab
http://tools.openlab.psu.edu/tools/fetcher.php

MOTION CAPTURE:

Motion capture is the recording of actual human movement using video, magnetic, or
electro-mechanical devices.

Motion capture systems use some type of reflective, LED, magnetic, or acoustic marker that
is connected to the joints.

To produce a motion capture, the movements of a human are captured and then mapped to
a digital model. The capture records just the movements, not the physical appearance of the
model. The movements are much more natural looking, and much time (and cost) is saved.

14
Models can only perform movements that are anatomically possible. Using a system such as
MVN Analyser from Xsens (see video) also allows for the real-time capture of accurate
kinematic data.

In addition to the obvious use in animation and entertainment, motion capture can also be
used to analyse how different users interact with a product, with the goal of improving
safety and ergonomics.

Watch the video: https://www.youtube.com/watch?v=CJ-ehBIfXEg

[In this video from Xsens, we can see how motion capture technology is used to understand human factors and
ergonomics in various design contexts]

Watch the video: https://www.goodmorningamerica.com/video/embed/48604313

Figure 8: Combination of Motion Capture and Digital Humans in Seimen's Technomatix software used to
analyze ergonomics in a vehicle.

HAPTIC TECHNOLOGIES:

Haptic technologies use the sense of touch to provide feedback to the user. When interact
with haptic technologies when our mobile phone vibrates when you press a button. More
recently, some touch pads on notebook computers provide haptic feedback to the user as
the move the mouse around the screen. It is also used in many gaming consoles

Haptic technologies allow the user to interact more closely with the computer simulation
and to respond to feedback from the system. Remote surgery systems rely on haptic
feedback to communicate to the surgeon the nuance of the operation.

Watch the video on https://www.youtube.com/watch?v=uPnHzQ7qJ2Y

15
Figure 9: The haptic glove, the AxonVR, uses micro-pockets of air in the touch surfaces to communicate touch
to the user.

Figure 10: Apple's Force Touch trackpad used in MacBook Pros

Figure 11: Remote surgery, BBC

16
VIRTUAL REALITY (VR):

Virtual reality technologies create a virtual environment where the user can interact with it
in a realistic way. VR technologies rely on wearable technologies such as a helmet and
goggles as well as haptic technologies to provide feedback to the user.

As seen in the video of Ford's Immersive Vehicle Environment Lab, VR technologies can
provide valuable feedback about the design, ergonomics, use, and safety of a design.
Because of its virtual nature, changes can be easily and quickly tested, saving time and
development costs.

In addition, valuable data can be gathered about how users interact and use a product.

Watch the video: https://www.youtube.com/watch?v=wbx8ios3vd4

[Ford's Immersive Vehicle Environment Lab is used to evaluate safety and ergonomic features of a
car. Note how the system uses a combination of VR, Haptic, and Motion capture technologies.]

Watch the video: https://www.youtube.com/watch?v=Xh_Cx_NUO88

[Hyundai uses VR Tech as part of the design process to explore ideas, collaborate, and test concepts.]

ANIMATION:

Animation can be used to simulate a process. It can be used to confirm the placement of
equipment and determine safety, ergonomics, and efficiency of a factory layout.

Animation can also be used to communicate form and function of a product.

Watch the video: https://www.youtube.com/watch?v=r6x0aJ59jc0

[Technical animation of 3D CAD]

17