Prototyping

Teaching materials to accompany:

Product Design and Development
Chapter 14
Karl T. Ulrich and Steven D. Eppinger
5th Edition, Irwin McGraw-Hill, 2012.
 Product Design and Development
Karl T. Ulrich and Steven D. Eppinger
5th edition, Irwin McGraw-Hill, 2012.
Chapter Table of Contents:
1.Introduction
2.Development Processes and Organizations
3.Opportunity Identification
4.Product Planning
5.Identifying Customer Needs
6.Product Specifications
7.Concept Generation
8.Concept Selection
9.Concept Testing
10.Product Architecture
11.Industrial Design
12.Design for Environment
13.Design for Manufacturing
14.Prototyping
15.Robust Design
16.Patents and Intellectual Property
17.Product Development Economics
18.Managing Projects
 Product Development Process

Concept
Concept System-Level
System-Level Detail
Detail Testing
Testingand
and Production
Production
Planning
Planning Development Design Design Refinement Ramp-Up
Development Design Design Refinement Ramp-Up

Prototyping is done throughout the development process.

 Concept Development Process
Mission Development
Statement Identify Establish Generate Select Test Set Plan Plan
Customer Target Product Product Product Final Downstream
Needs Specifications Concepts Concept(s) Concept(s) Specifications Development

Perform Economic Analysis

Benchmark Competitive Products

Build and Test Models and Prototypes

 Prototyping Example:
Apple PowerBook Duo Trackball
 Outline
• Definition
• Steps in prototyping decisions
• Purposes of prototypes
• Principles for choosing a prototype type

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 Definition
• An approximation of the product
along one or more dimensions of
interest.
• Physical prototypes vs. analytical
prototypes
• Comprehensive (with all the
attributes of a product) vs. focused
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 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
 Purposes vs. prototype types
• Focused analytical
– Learning
• Focused physical
– Learning and communication
• Comprehensive physical
– Learning, communication, integration, and
milestones.

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 Prototype decision
(technical risk vs. prototype cost)
• Low risk- low cost (e.g., printed matters)
– No need for comprehensive prototypes
• Low risk – high cost (ships, buildings)
– Can’t afford comprehensive prototype.
• High risk – low cost (software)
– Many comprehensive prototypes
• High risk high cost (airplanes, satellites)
– Use analytical models extensively
– Carefully planned comprehensive prototypes
– Sell the first unit

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Physical vs. Analytical Prototypes
Physical Prototypes Analytical Prototypes
• Tangible approximation of • Mathematical model of the
the product. product.
• May exhibit unmodeled • Can only exhibit behavior
behavior. arising from explicitly modeled
phenomena. (However,
• Some behavior may be an behavior is not always
artifact of the anticipated.
approximation. • Some behavior may be an
• Often best for artifact of the analytical
communication. 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.
 Principles for choosing a
prototype type
• Analytical prototypes are in general more flexible
than physical prototypes
• Physical prototypes are required to detect
unanticipated phenomena
• Prototypes may reduce the risk of costly iterations
• Prototypes may expedite other development steps
– Example: add a prototyping step in the part design-mold design-
molding process

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 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”.
 Prototype technologies
• Traditional prototyping methods
• 3D computer modeling
• Free-form fabrication
– Stereolithography
• Using various materials including wax, resin, paper,
ceramics, and metals.
– Lamination
• Using paper cut, lay by layer
– Rapid prototyping
• Laser curing (solidifying) soft materials such as resin, layer
by layer
– 3D printing
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 Traditional Prototyping Methods

• CNC machining
• Rubber molding + urethane casting

• Materials: wood, foam, plastics, etc.

• Model making requires special skills.
 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...
 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

Other Images
Prototyping
Chapter 12
EIN 6392, Product Design
summer 2012
 Steps
• Define the purpose of the prototype
• Establish the level of approximation of the
prototype
• Outline an experimental plan
• Create a schedule for procurement,
construction, and test
• Plan milestones for prototypes (alpha, beta,
pre-production)
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