Introduction

The Virtual and Augmented Reality industry is set to change the way immerse ourselves in
virtual environments. Forecasted to be worth 120 billion by 2020 [1], industries within the
product design, engineering and architecture will face a grand shift in how our products
are designed and experienced.

The assignment focuses on designing and manufacturing a simple VR headset, and identi-
fies 5 CAD/CAM technologies of which could significantly improve the design and manu-
facture of a VR headset. In terms of structure the case study is divided into 5 sections.

Figure 1: VR Model - Isometric View

Each section focuses on the relevant CAD/CAM tool and its corresponding return of invest-
ment upon being applied to the design, prototyping and fabrication of a VR headsets. The
software licenses required to purchase each CAD/CAM tool has been estimated for a design
team of 5 within a manufacturing enterprise.
C o l l a b o r a t i ve t o o l s

With the development of cloud computing technologies, entire CAD software packages
and functionalities are able to be deployed on the internet in some examples allowing us-
ers to design CAD models through their browser [2]. The key feature, however, lies in users
ability to collaborate and share designs amongst each other through cloud technologies.
Collaborative design offers multiple objectives: optimizing the mechanical function of a
product, minimizing production or assembly costs, and thus ensures that the product can
be easily and economically operated [3].

Figure 2: VR Model - Back Isometric View

Collaborative tools also enable designers to share product models, as well as related data,
from geographically distant locations [4]

Applying the functionalities of collaborative CAD tools when designing a VR headset can
allow multiple designers to inspect the model and provide feedback for which parts of
the model require iteration [5]. Furthermore, in order to share CAD models - collaborative
designers can store design files in a neutral file format [6]. This allows CAD data to be trans-
ferred from one CAD tool to another over the Internet.
Investing in collaborative CAD tools provide wide scope for design process improvement.
In a recent case study, HP achieved a 135% return on investment after one month, which
increased to 240% after three months upon using collaborative CAD tools [3]. The use of
collaborative CAD tools also suggests that design organisations are able to launch their
product quicker to market, as pooling together CAD models on a global online database
reduces the time of having to send models to one another through offline workflows.

CAD collaboration tools are currently available on Solidworks PDM Software Package [7].
The software package contains collaborative tools to allow designers to interact with one
another through the cloud. For a small enterprise team of 5 CAD Designers, 5 Licenses can
be accounted for approximately 8,000 [8]. If we were to assume an hour is lost a day when
designers collaborate with offline practices, then 30 hours of time lost a month may be the
difference between being a pioneer or a follower in the VR industry. Hence it can be consid-
ered to invest in collaborative design tools for a small-to-medium enterprise design team.

Design Visualisation

After the design process, prototyping comes next. Prototyping from its digital form to
its physical, enables designers to inspect their models and to identify any faults of which
would be improved upon in the subsequent design iteration [9]. However, fabricating
physical models poses its challenges. Firstly, they are complex and expensive to make.
Secondly, they take time to be fabricated. The complexity, high costs and time taken may
shape the difference between a quick-to-market product and its corresponding followers.

Design Visualisation promises to help communicate and review the visual aspects of a
design in a better manner. This helps provide the individual with a detailed investigation
in the 3D model, providing highest degree of photo-realisms without the need for larger
group reviews. [10]
Design visualisation allow users to manipulate and interact with photorealistic 3D models
in real time [11]. In this case, users would be able to view 3D VR models up close and be
able to inspect various design elements. This subsequently allows users to make confident
designs decisions on digital data sets.
3D IVR enables users to examine several scenarios and alternatives simultaneously and pro-
vides high level of presence and interactivity with the proposed alternatives. This is very
essential for decision makers knowing that 83% of new information is learnt through sight
[12].

Figure 3: VR Model - Right View

Minimising the use of physical models where cost and lead time are an important factor
helps develop a more validated design quickly. Apart from this, the majority of users
confidently rate 3D IVR technology as a significant contributor towards their understand-
ing of the presented product. This indicates the superiority of 3D IVR over 2D as a commu-
nication tool [13].

Autodesks CAD software product VRED provides a workplace for generation 3D imagery
and animations which can be used for previsualising 3D models [14]. A yearly license of
684 can be grouped for a 5 person design team at 3420 [15]. Using traditional methods
such as injection moulding or die casting for VR models can lead up to high costs from cost
parameters such as: as thermoplastic materials, tooling operational costs and labour costs.
Rapid Prototy ping

Additive Layer Manufacturing is the fabrication of a part by building up and solidifying a

series of layers. It is the process of making a 3D solid object by adding material and usually
refers to end-use industrial parts [16].

Fabricating parts layer by layer gives the designer more freedom for a few reasons. Firstly
no tooling is required as the part is fabricated via a single form of extrusion. Secondly, it
enables designs to print more complicated models as additive manufacturing simplifies
the process by converting complex geometry into printable features. Lastly, every part can
produced as one solid part; reducing the need to assemble the various components [17].

Rapid Prototyping can be used to fabricate 3D models in order be analysed and assessed
in term of model quality [18]. In addition, rapid prototyping reduces development time
and time to market. Any feedback obtained from inspecting the model would then be im-
plemented into the next design iteration. As a result, rapid prototyping helps product de-
signers develop prototypes quickly and cheaply compared to traditional manufacturing
methods.

Fused Deposit Modelling is recommended for prototyping the Virtual Reality Headset [16].
Machines which use Fused Deposition Modelling are recommended as they can 3D print
models at medium resolution, print complex and large parts and offer a range of thermo-
plastics. Therefore, investing in rapid prototyping tools such as 3D printing significantly
reduces product manufacturing costs.

While the price for most 3D printers may have a high price, the amount of finance saved by
eliminating routine product manufacturing costs such work-holding, labour and tooling
costs can outweigh that of traditional manufacturing methods.

It should be noted that initial costs for purchasing a 3D printer may outweigh the opera-
tional costs of using traditional prototyping methods. However, assuming that an array of
prototypes can be printed in the following months, the benefits of purchasing a 3D printer
to print a large quantity of prototypes outweigh that of not purchasing a 3D printer and
remaining with previous manufacturing methods.

Figure 4: VR Model - Back View

Parametric Modelling
Parametric Modelling involves manipulating the geometry of a 3D model via design param-
eters [19]. These parameters can be displayed in an intuitive and user-friendly manner such
as parametric sliders, and drop-boxes, leading to improvements in design representation.

Using direct modelling, designers can manually manipulate lines, shape surfaces and can
change the perspective of their models. Parametric modelling on the contrast, allows de-
signers to classify parts of their designs and thus adjust group parts of their designs in one
edit [20]. This can significantly reduce time in having to edit parts of the work; especially
once feedback has been obtained from rapid prototyping in order to be looped into the
design process.

In the VR case, parametric modelling can group parts of the model creating somewhat of
a design system. However, prerequisite experience in parametric modelling is required in
order to certify a high quality parametric model of a Virtual Reality headset.

Grasshopper is a popular parametric modelling tool and is a free plugin for Rhino3D a
popular 3D modelling tool used primarily in designing consumer orientated products [21].
A software license for an enterprise of 5 designers can account to a total of 4,300 (Rhino 5
for Windows is currently priced at 860 approximately) [22].

Parametric reduces product time to market and overall labour costs; whilst overall provid-
ing a new opportunity for representing 3D models [23]. Training courses may need to be
supplied in order to bring designers on par with parametric modelling; though the benefits
of adopting parametric modelling in the CAM process outweigh that of not adopting par-
ametric modelling.

Figure 5: VR Model - Feature Highlighted Right View

CAM Automation
Automation can play an important role, shortening manufacturing lead times and improv-
ing quality and consistent performance while requiring less skilled, less expensive resourc-
es [24]. This is due to the fact that manual CNC programming relies heavily on the skillsets
available by operator [25]. CAM automation aims to reduce human error by providing a de-
gree of computer intelligence within manufacturing processes such as CNC programming.

Autodesks FeatureCAM offers to automate the workflow from design to NC Code [26]. This
can be achieved by implementing functionalities including though not limited to Feature
Recognition, Programming Control and Collision Avoidance with the manufacturing work-
flow. This aims to reduce programming time when fabricating VR Headsets, in this case, and
thus reduces time-to-market when developing a fully functional product of high quality.

FeatureCAM Ultimate 2017 software package (which includes subsidiary software tools
such as Autodesk PartMaker 2017 and Autodesk Manufacturing Data Exchange Utility) can
be purchased for a total cost of 260 (approximately 50 per software license) [27]. Using
FeatureCAM leads to reduced design iterations as automated CNC programming is able to
work out tool paths more efficiently.

Conclusions

From immersing users into virtual worlds to enhancing the creative experience of a de-
signer VR promises a new form of entertainment and design for future to come. With the
continual rise in improvements in CAD/CAM technologies; VR manufacturing organisations
are able to focus their strategic objectives towards developing VR products more efficiently
and at a higher level of manufacturing quality.

Figure 6: VR Model - Isometric Wireframe View

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3D VR Model Inspired by GrabCAD.com