Prototyping

BMA4813
What is a Prototype?
 A prototype is an early sample, model, or release of a product built to
test a concept or process or to act as a thing to be replicated or learned
from. It is a term used in a variety of contexts, including semantics,
design, electronics, and software programming.
 A prototype is designed to test and try a new design to enhance
precision by system analysts and users. Prototyping serves to provide
specifications for a real, working system rather than a theoretical one.
In some workflow models, creating a prototype (a process sometimes
called materialization) is the step between the formalization and the
evaluation of an idea.
 The word prototype derives from the Greek πρωτότυπον prototypon,
"primitive form", neutral of πρωτότυπος prototypos, "original,
primitive", from πρῶτος protos, "first" and τύπος typos, "impression"
1st Concept Formulation…

01 : CONCEPT DEVELOPMENT

 
Every new vehicle development begins with Concept Formulation: a
                                                                            

brainstorming process placing you, the consumer, at the centre of the idea:
trying to forecast exactly what you will expect and need from your car, through
                          

studying styling trends and product segmentation, several years before you’re
even started thinking about buying it.

Idea Sketches are hand-drawn, and modelled using computer tools like ALIAS.
Miniature Scale (1:3 ratio) are built, and upon concept approval, the concept
will progress to the Design Development phase
2nd Design Development…

                                                                              

                         
• This phase of the development begins to fill in the details
of the concept car, supported by sophisticated digitising
layout planning computer modelling software which
creates external surface (A-surface) data for form and
shape.

A 1:1 full-size scale model is built, finished and painted,

and if this is approved, a Styling-Engineering Feasibility
study examines the practicality of body engineering and
car internal systems installations, while 3D computer
modelling adds refinements to the computer simulated
model, together with internal surface data (B-surface).
3rd Engineering & Testing…

03 : ENGINEERING & TESTING DEVELOPMENT

                            

              
• Engineering Development. From the Model Fix, engineers
produce component drawings and simultaneously simulate the
properties of body shell rigidity, strength and crashworthiness, using
Computer Aided Engineering (CAE) to comply to safety standards.
Prototype Development. Soft Tooling parts are developed with the
specified designs & materials. PROTON’s Prototype Shop is able to
assemble and produce the Final prototype car testing & validation.
Testing Development. Offering comprehensive testing for
Component, Material, Safety, Strength and Complete Vehicle
Validation. PROTON facilities are the best in South-East-Asia, able
to conduct various validation roles ensuring vehicles meet specified
standards and safety requirements.
RnD Facilities…
 Aim…Comparison Current Vs Proposed ...
0 5 10 15 20 25 30 35

10 9 16 14 23 19 36 27
MASTER SCHEDULE

Model Fix F2 drwg

F1 drwg P0 drwg P0 build SOP

F1 Drwg Prepn F2 Build P1 Build NO P2

BUILD

F1 Proto Build P0 Build PP Build

Tooling Design [8 7 Months]

TOOLING EVENTS

Tooling Fabrication [10 8 Months]

Tooling Single Tryout, EO Modify & Buy-Off [16 14 Months]

Line Trials [6 5 Months]

COURTESY OF PROTON
Vehicle Platform…
Powertrain Engineering…
Homologation & Testing…

Components and material tests

Safety, Strength, Ride & Handling Test…

Sled Test

Multi Axial Road Simulator

4 poster
Roof Crush

Seat Belt Anchorage

White Body Test

Emission Development Test…

Chassis Dyno & Cold Chamber

Engine Dyno
Noise Lab…
Prototype Center…

CONCEPT CAR 1:3 SCALE MODEL

Here is a 1:3 scale model of a concept car which has been finished,
painted and detailed. It provides an exact replica of what car would
look like from every angle, if it were to be produced.
Prototype Center…
THE CLAY MODELLING PROCESS

Clay modelling helps designers to process 3 - dimensional information about

car designs faster and more efficiently during the development process.

First a white-foam core is shaped, around which the raw clay will be machine-
layered to build up the correct thickness of material.

Meticulous hand - crafting is then required, in shaping and detailing every

surface of the model to match the designers and stylists concept.
Rapid Prototype
RAPID PROTOTYPING
MANUFACTURING CENTRE

These samples are from PROTON’s

cutting edge prototyping facilities,
which offer Stereo Lithography
Apparatus (SLA), Laminated Object
Manufacturing, and Rapid Mould
Making for plastic or alloy parts.

This service has become a revenue

generator in its own right, and works
with many external clients on various
types of projects.
Soft tools
Soft tools
• Soft tool parts are normally produced by using simple tooling
method such as resin die to form the parts. To complete the process
the use of hand tools and laser cutting is extensively utilized.

• This is because the quantity required for F1 build–up is ranging

from 20 to a maximum of 50 cars depending on the needs and
requirements. At this stage, especially for the special material, soft
tool maker uses as close as possible the intended design material in
producing the parts in order to get a good result during F1 build-up.

• It takes between one to three months to prepare the soft tool parts
depending on the sizes and complexity of the part shapes.
 Mule
A development mule (test mule, or simply mule) in the automotive
industry is a testbed vehicle equipped with prototype components
requiring evaluation. They are often camouflaged to deceive competitors
and thwart a curious automotive press.
 Mule
• Mules are necessary because automakers must assess new aspects of
vehicles for both strengths and weaknesses before production. Mules
are drivable, often pre-production, vehicles, sometimes years away from
realization (in the wake of a concept car that lacked critical mechanical
components).

• Mules may also have advanced chassis and powertrain designs from a
prospective vehicle that need testing, effectively achieved concealed in
the body and interior of a similarly sized production model.

• If no comparable vehicle is available in-house or an external benchmark

is being used mules may be based on another manufacturer's model. For
example, in the 1970s the first-generation Ford Fiesta was developed
using mules based on the then class-leading Fiat 127, as Ford had no
comparable compact model of similar size to utilize.
 Mule
• Mules are also used to conceal styling changes and visible telltales of
performance alterations in near production vehicles, receiving varying
degrees of camouflage to deceive rival makers and thwart a curious
automotive press.

• Such alterations can span from distracting shrinkwrap designs to

substituting crude cylindric shapes for taillights, non-standard wheels,
or assemblages of plastic and tape to hide a vehicle's shape and design
elements.

• Development mules are often used very heavily during testing and
scrapped. Occasionally they are acquired by members of the
automaker's engineering team or executives overseeing the design
process.
Process…
• Once the soft tool parts are ready, F1 build-up is commenced at the
prototype shop by using manual assembly station.

• The station is equipped as much as possible to represent the actual

production line set-ups. However, the main purpose of F’s build is to
verify the product design against the clay model, therefore, production
requirements are becoming less priority.

• Every build has its own purpose such as assembly check, appearance,
crash test, components fitting and engine test. Thus, prototype build is
a long waited event by each department to test its individual
requirements.
• From the fittings and testing, the departments come out with their
analysis and results that are reflected in the F2 drawings preparation.

• Similarly, the activity cycle is done for F2 builds except for the results
are used for production requirements. The outcome from F2 result is
presented in the management meeting which is called Design Quality
Confirmation Meeting (DQCM), whereby the management decides and
confirms the built car is according to design intent.
Test Track…