Prototyping
Teaching materials to accompany:
Product Design and Development
Chapter 12
Karl T. Ulrich and Steven D.Eppinger
2nd Edition, Irwin McGraw-Hill, 2000.
Product Design and Development
Karl T. Ulrich and Steven D.Eppinger
2nd edition, Irwin McGraw-Hill, 2000.
Chapter Table of Contents
1. Introduction
2. Development Processes and Organizations
3. Product Planning
4. Identifying Customer Needs
5. Product Specifications
6. Concept Generation
7. Concept Selection
8. Concept Testing
9. Product Architecture
10. Industrial Design
11. Design for Manufacturing
12. Prototyping
13. Product Development Economics
14. Managing Projects
Product Development Process
Concept Development Process
Prototyping Example:
Apple PowerBook Duo Trackball
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 teams schedule
e.g., first testable hardware
Types of Prototypes
Physical vs. Analytical
Prototypes
Physical Prototypes
Tangible approximation of
Analytical Prototypes
Mathematical model of the product.
the product.
May exhibit unmodeled
behavior.
Some behavior may be an
Can only exhibit behavior arising
artifact of the
approximation.
Often best for
communication.
Some behavior may be an artifact
from explicitly modeled
phenomena. (However, behavior
is not always anticipated.
of the analytical method.
Often allow more experimental
freedom than physical models.
Focused vs. Comprehensive Prototypes
Focused Prototypes
Implement one or a few
attributes of the product.
Answer specific
questions about the
product design.
Generally several are
required.
Comprehensive Prototypes
Implement many or all
attributes of the product.
Offer opportunities for
rigorous testing.
Often best for milestones
and integration.
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
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.
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
Traditional Prototyping Methods
CNC machining
Rubber molding + urethane casting
Materials: wood, foam, plastics, etc.
Model making requires special skills.
