ME515 Integrated Product design and Prototyping

Module 5

Modern Approaches to Product Design

Concurrent Engineering

With the latest development due to globalization, business units must have the capacity to deal with
the increasing competition. This is possible only by drastic organizational productivity improvement.
One of the tools to achieve the organizational productivity improvement is 'Concurrent Engineering'.
New product planning and development is considered to be a critical stage in the entire business
process. If there is a delay of three months in bringing a product to the market, it would cause an
enormous loss to the organization by way of reduced market share.

Concurrent engineering, also called parallel or simultaneous engineering, is a new philosophy,

viewed by most corporations as a means to competitive, world class manufacturing. It strives to do
the right job the first time. It results from synthesizing the two fundamental observations which are
given below:

1. The changes become more and more costly, and these changes are incorporated in the project
later.

2. Performing different steps of a project in parallel, would complete the project more quickly than
executing the steps sequentially, one after the other.

Another important aspect of concurrent engineering is to implement the idea of designing a product
for its life-time use and environmentally safe recycling of the product at the end of its life (i.c. life-
cycle engineering).

The key to concurrent engineering is that the entire development process is managed by a cross-
functional team of experts from all relevant departments, including marketing, materials, design and
manufacturing. The central notion is that the team is responsible for conceptualizing the product
correctly, thereby dramatically reducing the changes to be made later. Also, the team manages
parallel processing, reduces delays and waste. If the design team makes decisions without having
adequate knowledge of the capabilities of the manufacturing process, corrections will be needed in
the downstream process, which are very expensive and time consuming. Concurrent engineering
avoids all such situations.

Concurrent engineering achieves reduction in cost, improvement in quality and reduction in

throughput time of a product development process. These attributes of concurrent engineering
enable us to plan and bring the product to market in time. The team of experts in concurrent
engineering are Production engineers, Prototype engineers, Product design and testing engineers,
Marketing personnel, Purchasing personnel, Finance personnel, and Principal vendors of
manufacturing equipment and components.
Concurrent engineering is a kind of Business Process Reengineering specifically applied to product
development. Before introducing concurrent engineering, the following must be understood.

Psychology of the top management.

The decision of implementing concurrent engineering is a strategic decision. So, the top
management's involvement in this activity is highly essential.

Philosophy of the organization.

Everyone must make sure that the design has a customer focus and the design is closely related with
the rest of the organization.

Methodology of the activities.

The different tools which are used in concurrent engineering should aim to achieve the following:.
Reduction in cost. Improvement in quality, Reduction in throughput time of a product.

Tools for concurrent engineering

Design for Assembly (DFA).

Significant portion of the manufacturing cost is decided at the design stage of the assembly. The
product assembly consists of a set of components which are to be assembled as per the well-defined
assembly sequence among the components. Once, this is finalized, then the team may concentrate
on part reduction and simplification process. Each part in the design is examined for the following
conditions.

How the part is to be grasped, oriented, and moved for insertion/assembly?

How it is inserted and/or fastened into the product?

Similar to method study which will be discussed later under work study, a series of questions are to
be asked with respect to the following aspects:

.1. Necessity of the part itself in the [Link] the part is necessary, the size,

2. shape and material are to be questioned. [Link] level of quality required.

Design for Manufacturing (DFM).

DFM aims to estimate the cost of the proposed product based on rough geometry of the product.
The purpose of DFM cost estimating analysis is to enable design teams to weigh alternative designs
and various production process, quantify manufacturing cost, and make the necessary trade-off
decision between parts consolidation and materials/manufacturing costs.

The benefits of design for manufacture are listed below:

It serves as a cost estimator.* It is considered to be a key to concurrent engineering.

It is an effective vendor negotiating aid. It is considered to be a competitive bench marking tool.

Quality Function Deployment (QFD).

QFD is an add-on to TQM by designing and manufacturing product or service as per customer
preference and satisfaction. Design engineer can convert customer needs into engineering
specifications using QFD. A QFD matrix helps in translating customer needs even before finalizing
concept specifications. The conceptual definition of the product is done in a better way by QFD. So,
QFD translates the preference of customers into products features and also establishes quality
based on fitness for use.

Failure Mode Effects and Criticality Analysis (FMECA).

FMECA is a technique for assessing the risk associated with defective products reaching the market.
The technique assesses the following three aspects of the system and optimizes them:

Every possible failure mode, Effect of each failure mode on the product, The criticality of the effect
of each failure mode on the product. Also, it suggests the action to be taken to compensate for the
effect due to every failure mode.

CAD, CAM/CAE.

The application of computers in design and manufacturing constitutes the most significant
opportunity for substantial productivity gains in industry today. It is expected that this trend towards
computerization will ultimately lead to the computer integrated automatic factory' very soon.

Companies implementing concurrent engineering should possess CAD/CAM systems. It is advisable

to have atleast CAD system in the organization to speed up the design and redesigning procedures.
With right application of hardware and software, it is possible to develop the final design with fewer
prototypes which, in turn, will reduce the lead time of product development. CAD/CAM refers to the
integration of computers into the entire design to production cycle of a product.

Computer Aided Engineering (CAE) is the analysis of a design for error checking, or optimize
manufacturability, performance and economy. Information drawn from the CAD/CAM database is
used to analyze the functional characteristics of a product, part or system and design and to
simulate its various performance. Concurrent engineering provides common database for new
products or existing products to all departments in the form they require and processing of these
data os required. The type of data that are available in the database are as follows:

Design data for product and component supplier, Functional design specifications for specialist
suppliers,Manufacturing data for manufacturing engineers,Specification for cost analysis for
accountants,Specification in product features, for marketing.

RAPID PROTOTYPING

During product design, physical models called prototypes are prepared and evaluated as a part of
design evaluation. Conventional prototype manufacture is a very time-consuming process involving
all stages of manufacture such as process planning, machining, and assembly, in addition to
production planning. Due to the delay caused by the conventional prototyping procedure, R&D
people in industry and academics started looking for some strategy which could enable the
conversion of a 3D computer model to a 3D prototype form. Thus, the need of industry to reduce
time to market resulted in the unique concept of rapid prototyping.

Principle of Rapid Prototyping

In the rapid prototyping process, the 3D object is sliced into several 2D sections on a computer. This
simplifies 3D part producing process to 2D layer manufacture. By ‘gluing’ the produced layers, the
desired part can be produced directly from its geometric model. Thus, rapid prototyping consists of
two steps; Data preparation and Model production.

Rapid Prototyping Technologies

(i) Stereolithography.

In this technology, the part is produced in a vat containing a liquid which is a photo-curable resin
acrylate (see Fig.1(a)). Under the influence of light of a specific wavelength, small molecules are
polymerized into larger solid molecules. The SLA machine creates the prototypes by tracing the layer
cross-sections on the surface of liquid polymer pool with a laser beam. In the initial position the
elevator table in the vat is in the topmost position. The laser beam is driven in x- and y-directions by
programme driven mirrors to sweep across the liquid surface so as to solidify it to a designed depth
(say, 1 mm). In the next cycle, the elevator table is lowered further. This is repeated until the 3D
model is created. Figure 1(b) shows a modified design in which a contact window allows the desired
area to be exposed to light, masking the area which remains liquid.

(ii) Photomasking technique or solid ground curing.

This method has certain unique features: 1. A mask is generated by electrostatically charging a glass
plate with a negative image of cross section of the part. 2. In the meantime, a thin layer of liquid
polymer is spread across the surface of the workplane. 3. The mask plate with negative image of the
cross-section slice is positioned over the thin polymer layer and exposed under the ultraviolet laser
lamp for two seconds. All the parts of the exposed photopolymer layer are solidified with one
exposure. However, the area shaded by the mask is left in a liquid form and is wiped off with vacuum
suction head and replaced by hot wax which acts as a support to the solidified polymer layer. 4. A
face mill makes the surface of wax and polymer flat and to desired thickness. 5. The above four steps
are repeated until the final model which is embedded in wax is obtained. The wax can be removed.
(iii) Selective laser Sintering (SLS).

In the SLS process, a thin layer of powder is applied at the workplace with a roller. Carbon dioxide
laser is often used to sinter successive layers of powder (instead of liquid resin).

Particles of 50 micro diameter, are molten by laser beam. Solidified layer is lowered in powder bed
by piston and new layer is spread over the surface

(iv) Fused deposition modelling.

In the FDM process (Fig 3), a spool of thermoplastic filament feeds into a heated FDM extrusion
head. The x- and y-movements of the FDM head are controlled by a computer so that the exact
outline of each cross-section of the prototype is obtained. Each layer is bonded to the earlier layer
by heating. This method is ideal for producing hollow objects.

The heated thermoplastic material filament coming out of the conical hopper is deposited in X and Y
direction under the instruction from computer. The table is lowered in Z direction of each cycle of
deposition.

(v) Laminated object manufacturing (LOM).

The LOM process (Fig 4) is especially suited for producing parts from bonded paper, plastic, metal,
etc. A laser beam cuts the countour of part cross-section. Several such sections, when glued or
welded, yield the prototype.

In this process, laser beam cuts contour of each layer and glue activated by hot roller presses the
layers together. The cross hatch material remaining in the final object is removed later on. For
example, if the object is an octagonal prism with a circular hole in the middle, the cross hatched
material remaining attached to the object is removed after the process is complete.
(vi) Ballistic particle manufacturing (BPM).

The BPM system uses piezo-driven inkjet mechanism to shoot droplets of molten materials, which
cold weld together on a previously deposited layer. A layer is created by moving the droplet nozzle
in x- and y-directions. After a layer is formed, the baseplate lowers a specified distance and a new
layer is created on top of the previous one. Finally, the model is created.

(vii) Three-dimensional (3D) printing.

Three-dimensional printing was developed at the MIT (USA). This technique also uses an inkjet
printing head with a binder material to bind ceramic and other powders which are spread by a roller
prior to application of the binder gun. The aforementioned methods of rapid prototyping are still in
a stage of development, even in developed countries. In India, intensive research is in progress at
the Indian Institute of Technology Bombay and the Indian Institute of Science, Bangalore.

Referring to Fig. 14.12, the parts are built upon a platform situated in a bin full of powder material.
An inkjet printing head selectively ‘prints’ binder to fuse the powder in the desired areas. Unfused
powder does the function of supporting the part. The platform is lowered, more powder and binder
is added and leveled, and the process is repeated. When finished, the green part is sintered and then
removed from the unbound powder.

Virtual Prototyping

Virtual Reality is a set of interface technologies designed to make the user feel “present” in a new
environment or experience, rather than feeling like an outside observer. Virtual reality is defined as
“a computer-generated simulation of a three-dimensional environment that can be experienced and
interacted with in a seemingly real or physical way.” AR, on the other hand, is defined as “a
technology that superimposes digital information and images onto the real world, using a device’s
camera and display.” Both VR and AR are used to create an immersive experience for users, but VR
provides a completely virtual environment, whereas AR enhances the real world.

The Role of Virtual Reality in Product Design and Prototyping

Traditional product design methods involve a series of steps including conceptual sketches, digital
modelling, physical prototyping, and testing. These processes can be time-consuming and costly,
requiring multiple iterations and a trial-and-error approach.
The introduction of VR tools and software has significantly transformed these practices. Now,
designers can create and interact with their models in a 3D environment, offering a more intuitive
understanding of space, ergonomics, and aesthetics. Software platforms like Autodesk VRED, Gravity
Sketch, and Unreal Engine allow for real-time collaboration, modifications, and visualisation.

By using VR in product design and prototyping, companies can avail of smaller development times,
lower costs associated with physical prototyping, and greater creative freedom. VR in business also
makes user testing more streamlined, allowing for real time analysis and feedback, making the final
product more user centric.

VR technology marks a potentially gigantic leap in product development by allowing designers and
engineers to create, test, and refine their prototypes in a completely virtual and limitless
environment. Using such immersive technologies bypasses the need for physical models in the early
stages of development. This reduces production costs and expedites the entire process.

Prototyping with VR places users directly inside a 3D model of their – or someone else’s – design,
allowing a deeper understanding of how it would function in the real-world. Users can interact with
the prototype, adjust in real-time, and observe the effects immediately.

Industries such as automotive, aerospace, and consumer electronics have been among the first to
adopt VR prototyping in earnest. Car manufacturers use VR to explore new vehicle designs and
ergonomics, aerospace companies simulate aircraft components, and electronics firms test the
usability of devices before they’re manufactured.

The three main VR categories are the following:

 Non-Immersive Virtual Reality: This category is often overlooked as VR simply because it’s
so common. Non-immersive VR technology features a computer-generated virtual
environment where the user simultaneously remains aware and controlled by their physical
environment. Video games are a prime example of non-immersive VR.
 Semi-Immersive Virtual Reality: This type of VR provides an experience partially based in a
virtual environment. This type of VR makes sense for educational and training purposes with
graphical computing and large projector systems, such as flight simulators for pilot trainees.
 Fully Immersive Virtual Reality: Right now, there are no completely immersive VR
technologies, but advances are so swift that they may be right around the corner. This type
of VR generates the most realistic simulation experience, from sight to sound to sometimes
even olfactory sensations. Car racing games are an example of immersive virtual reality that
gives the user the sensation of speed and driving skills. Developed for gaming and other
entertainment purposes, VR use in other sectors is increasing.

The VR process combines hardware and software to create immersive experiences that “fool” the
eye and brain. Hardware supports sensory stimulation and simulation such as sounds, touch, smell
or heat intensity, while software creates the rendered virtual [Link] reality hardware
includes sensory accessories such as controllers, as well as headsets, hand trackers, treadmills and,
for creators, 3D cameras.
VR Headsets: A VR headset is a head-mounted device, such as goggles. A VR headset is a visual
screen or display. Headsets often include state-of-the-art sound, eye or head motion-tracking
sensors or cameras.

There are three main types of headsets:

PC-Based VR Headsets: PC headsets tend to be the highest-priced devices because they offer the
most immersive experiences. These headsets are usually cable-tethered from the headset and
powered by external hardware. The dedicated display, built-in motion sensors and an external
camera tracker offer high-quality sound and image and head tracking for greater realism.

Standalone VR Headsets: All-in-one or standalone VR headsets are wireless, integrated pieces of

hardware, such as tablets or phones. Wireless VR headsets are not always standalone. Some systems
transmit information wirelessly from consoles or PCs in proximity, and others use wired packs
carried in a pocket or clipped to clothing.

Mobile Headsets: These shell devices use lenses that cover a smartphone. The lenses separate the
screen to create a stereoscopic image that transforms a smartphone into a VR device. Mobile
headsets are relatively inexpensive. Wires are not needed because the phone does the processing.
Phones don’t offer the best visual experiences and are underpowered by game console- or PC-based
VR. They provide no positional tracking. The generated environment displays from a single point,
and it is not possible to look around objects in a scene.

VR Head set

VR Accessories

VR accessories are hardware products that facilitate VR technology. New devices are always in
development to improve the immersive experience. Today’s accessories include the 3D mouse,
optical trackers, wired gloves, motion controllers, bodysuits, treadmills, and even smelling devices.

These are some of the accessories used today in VR:

3D Mouse: A 3D mouse is a control and pointing device designed for movement in

virtual 3D spaces. 3D mice employ several methods to control 3D movement and 2D pointing,
including accelerometers, multi-axis sensors, IR sensors and lights.

Optical Trackers: Visual devices monitors the user’s position. The most common method
for VR systems is to use one or multiple fixed video cameras to follow the tracked object or person.
Wired Gloves: This type of device, worn on the hands, is also known as cyber gloves or data gloves.
Various sensor technologies capture physical movement data. Like an inertial or magnetic tracking
device, a motion tracker attaches to capture the glove’s rotation and global position data. The glove
software interprets movement. High-end versions provide haptic feedback or tactile stimulation,
allowing a wired glove to be an output device.

Motion Controllers: These accessories allow users to act in mixed reality. Controllers allow for fine-
grained interaction with digital objects because they have a precise position in space.

Omnidirectional Treadmills (ODTs): This accessory machine gives users the ability to move in any
direction physically. ODTs allow users to move freely for a fully immersive experience in VR
environments.

Smelling Devices: Smell devices are one of the newer accessories in the VR world. Vaqso, a Tokyo-
based company, offers a headset attachment that emits odors to convey the size and shape of a
candy bar. The fan-equipped device holds several different smells that can change intensity based
[Link] screen action

VR for Product Design / Manufacturing helps to Reduce need for physical prototypes, Facilitate
collaboration and critique, On-boarding for work in dangerous spaces, Pre-build simulation of factory
spaces and Safety training

Some VR disadvantages:

 Addiction: Some people become addicted to the VR experience in gaming and social media
applications. People can assume different identifies, which can be addictive and cause social,
psychological and biological issues.
 Health Problems: Extensive use of VR can create a loss of spatial awareness, nausea,
dizziness, disorientation and nausea, also known as simulator sickness.
 Screen Door Effect: When you use a headset, the display is within inches of your eyes. That
means you see pixels or the spaces between them, no matter how excellent the display
resolution may be. This mesh-like effect can irritate some users. Newer headsets have
improved but not eliminated the issue.
 Loss of Human Connections: When you rely on virtual connections rather than real-life
social interactions, trouble may result. Over-reliance on VR can lead to disassociation or
depression.
 Training Doesn’t Translate in the Real World: People trained in virtual reality may do well in
the app or platform but can’t perform to the necessary standard in real-world situations.

Expense: While prices are coming down, VR systems are not affordable for everyone.

Summary

Virtual Reality in product design and prototyping has a long way to go, but it has the potential to
revolutionise the field, transforming a traditionally time-consuming and iterative process into a more
efficient and collaborative one. From early-stage conceptualisation to user testing, VR empowers
designers with intuitive 3D visualisation tools, fostering innovation and streamlining development.
Beyond saving time and money, VR allows for real-time feedback and user-centric design, ensuring
products truly meet user needs. As VR technology continues to evolve, with advancements in haptics
and AI integration, the future of product design looks very bright indeed.