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Rapid Prototyping
Prototyping
• Prototyping is a quick way to incorporate direct feedback from
(real) users into a design.
• Purpose –
how it will look,
how it will feel,
how it will function,
where to get it made, and
how to make sure it will turn out the way one wants it.
• Sometime, very time- and cost-consuming process
• Must be a well-thought-out plan
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Commonly seen mistakes
• A common mistake is beginning a product development
project by constructing a full model of the final product
• Commitment too early to a particular design
• Gaining a false view of how long the system will take to
complete based on the time taken to prototype
• Too many design iterations that could lead to maintenance
and/or operational problems associated with previous
versions
• The performance characteristics of prototypes misled the
customer; and
• Utilizing materials or methods that do not reflect the final
design, leading to erroneous performance data.
Commonly seen mistakes
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Prototype classifications
Prototype of choice
• Analytical prototypes are generally more flexible than physical prototypes
• Analytical prototypes can be used to narrow the range of feasible parameters
• Physical prototypes can be used to fine-tune or confirm the design
• Physical prototypes are required to detect unanticipated phenomena
• Analytical models can seldom reveal phenomena that are not part of the underlying
analytical model
• A physical prototype often exhibits unanticipated phenomena completely unrelated to
the original objective of the prototype, for example, thermal, optical, electrical–
mechanical coupling, etc.
• A prototype may reduce the risk of costly iterations
• Anticipated benefits of a prototype may be weighted against time and money
• A prototype may expedite other development steps
• A prototype may restructure task dependencies
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Considerations
Before constructing a physical prototype, the following items
are kept in mind:
• Purpose
• Development time of prototype
• Possible forms
• Types of tests to perform
• Risk of constructing prototype or continuing without it
Before
Plan for Prototyping
• Step 1: Define the purpose of the prototype
• Step 2: Establish the level of approximation of the prototype
• Step 3: Outline an experimental plan
• Step 4: Create a schedule for procurement, construction, and
testing
• Step 5: Perform more detailed prototype planning that will
involve extensive time and cost
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Considerations
Before constructing a physical prototype, the following items
are kept in mind:
• Purpose
• Development time of prototype
• Possible forms
• Types of tests to perform
• Risk of constructing prototype or continuing without it
Before
PHYSICAL PROTOTYPE DESIGN PROCEDURE
• Task 1: Prototype Conceptual Design
• Task 2: Configuration Design of Prototype Parts and
Components
• Task 3: Parametric Design
• Task 4: Detailed Design
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PROTOTYPE PLANNING AND MANAGEMENT
Planning
• Communication
• Mentoring
• Brainstorming
• Resource allocation
• Tracking and measurement, and
• A good project manager
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PROTOTYPE PLANNING AND MANAGEMENT
• Secret to getting started on a prototype project is breaking
the complex overwhelming tasks into small manageable
tasks and
• Starting on the first one.
• Plan the tasks according to project objectives.
Project planning triangles
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PROJECT RISK MANAGEMENT
• Decision tree for risk management
• helps to make decisions in succession into the future
Squares represent decisions circles represent uncertain outcomes
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PROJECT RISK MANAGEMENT
• To evaluate the decision tree, start by assigning a cash value or
score to each possible outcome.
• Estimate how much it would be worth if that outcome came
about.
• The expected cash values (or scores) should be evaluated based
on the prototyping objectives.
• Take a look at each circle (representing an uncertainty point)
and estimate the probability of each outcome.
• If percentages are used, the total must total 100% at each circle.
• If fractions are used, these must add up to 1.
• If one has data on past events, one may be able to make
rigorous estimates of the probabilities. Otherwise write down
the best guess.
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PROJECT RISK MANAGEMENT
• Since the FDM process can end up with
the largest cash value,
Value for the physical prototype, in FDM process is – • It should be chosen as the process for
this case
• 0.8 (probability good outcome)* $5000 (value) = $4000 • Therefore, the recommended
• 0.1 (probability moderate outcome)*$2000 (value)= $200 prototyping method should be physical
• 0.1 (probability poor outcome)*0 (value)= $0 prototype— FDM process.
• The total expected value = $4200 - $1000 (FDM process cost) =
$3200
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COST ESTIMATION FOR PROTOTYPE
• When designing a product or a prototype, it is very critical
for a design engineer to learn about the cost factors—all
costs that can contribute to the final cost of the project.
• Many opportunities for product cost optimization are
embedded in the process of defining the project.
• Often it is too late to make a change in the later part of the
product development stage.
• A cost estimate establishes the base line of the project cost
at different stages of development of the project.
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COST ESTIMATION FOR PROTOTYPE
A good cost-estimate procedure includes –
• Uses best available data
• Adjusts data for definitions, accounting changes, time, unit
number of production
• Applies appropriate estimating techniques
• Addresses risk and uncertainty and
• Well documented
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COST ESTIMATION FOR PROTOTYPE
Activity-based costing classifies costs into four categories:
• Unit level—activities performed for each unit
• Batch level—activities performed for a group of product
units, such as batch or a delivery load
• Product level—activities performed for specific products or
product families
• Facility level—costs incurred to support the whole business.
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COST ESTIMATION FOR PROTOTYPE
• There is no simple way to estimate project costs, and each
method has strengths and weaknesses.
• Estimation should be based on several methods.
• If they do not return approximately the same result, some
action should be taken to find out more in order to make
more accurate estimates.
• There are several cost estimation methods
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COST ESTIMATION FOR PROTOTYPE
• Estimation by analogy
• Bottom–up estimation
• Top–down estimation
• Expert judgment
• Pricing to win
• Estimating models
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COST ESTIMATION FOR PROTOTYPE
Estimating models
• The cost equation for a particular device can be expressed as
below if it uses three parameters: number of component A,
number of component B, and time allowed for completion.
Where, n number of A components, m number of B components and t ime allowed
for completion in months.
The equation was devised as follows: The cost of component A is assumed to be
$500, and the cost of component B is assumed to be $800. The factor of 1.5 is to
allow for assembly/ welding since the amount of assembly/welding should be
proportional to the number of parts involved. The factor of 6 is to normalise the
typical amount of time required to complete one of these machines, 6 months.
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PROTOTYPE PLANNING AND MANAGEMENT
• High–low method
A regression equation is derived by
getting the two extreme limits of the
observations in the graph between a
dependent variable (total cost) and an
independent variable (activity measures).
• Graphical or scatter-graph method
• Inspection of accounts method
Looks at historical data and classifies
all expenses as fixed, variable, or
semi-variable.
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AN ESTIMATING MODEL FOR PROTOTYPING
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PROTOTYPING COST BREAKDOWNS
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PROTOTYPING AND MATERIAL PROPERTIES
For quick prototyping purposes, there are several materials
available –
• Modelling clay
• Machining wax
• Foam board
• Foam core
• Rubber, elastomer
• Cardboard, paper, cloth
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APPLICATION ISSUES IN SELECTING MATERIALS
• Force and load magnitude
• Creep (slow continuous deformation)
• Input loads
• Cyclic loads and fatigue
• Deformation
• In-service temperature
• Exposure to UV light (sunlight)
• Exposure to moisture
• Weather
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MATERIAL SELECTION PROCESSES FOR HIGH-FIDELITY PROTOTYPES
Material selection procedure: Material selection procedure:
material-first process-first
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RAPID PROTOTYPING PROCESSES
• Rapid prototyping (RP) is a freeform manufacturing process
that allows users to fabricate a real physical part directly
from a CAD (computer-aided design) model.
• The CAD model is sliced into many layers by any number of
software packages that can also prepare the part for
whichever layered manufacturing machine is to be used.
• The part is then built layer by-layer without extraneous
tools. This process allows us to quickly build geometrically
complex parts.
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RAPID PROTOTYPING PROCESSES: Broad Classification
•10.5937/fmet2001246Z
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RAPID PROTOTYPING PROCESSES: Subtractive Technology
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RAPID PROTOTYPING PROCESSES: Formative Technology
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RAPID PROTOTYPING PROCESSES: Additive Technology
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RAPID PROTOTYPING PROCESSES: Process chain
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Classification of AM Processes
Classification as per the ASTM – Vat photopolymerization
• Machine architecture and Powder bed fusion
AM Processes
• Materials transformation physics Material extrusion
Terminologies instead of using – Material jetting
• 1D Channel – point
Binder jetting
• 2X1D channel – point-wise
• Arrays of 1D channels – line
Sheet lamination
processing
• 2D Channel – layer Directed energy deposition
• Holographic-like techniques
– volume processing
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Ian Gibson, David W. Rosen, Brent Stucker, Additive manufacturing technologies: rapid prototyping to direct digital manufacturing Springer, 2010.
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Vat Photopolymerization Process
An additive manufacturing process in which liquid photopolymer in a vat is selectively
cured by light activated polymerization
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Powder bed fusion
An additive manufacturing process in which thermal energy selectively fuses regions
of a powder bed.
• Selective Laser Sintering (SLS)
• Selective Laser Melting
(SLM)/ Direct Metal
• Laser Sintering (DMLS)
• Electron Beam Melting (EBM)
• Multi Jet Fusion (MJF)
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Material extrusion - FDM
An additive manufacturing process in which material is selectively dispensed through a
nozzle or orifice.
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Material jetting
An additive manufacturing process in which droplets of build material are selectively
deposited
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Binder jetting
An additive manufacturing process in which a liquid bonding agent is selectively
deposited to join powder materials.
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Sheet lamination
An additive manufacturing process in which sheets of material are bonded to form an
object.
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Directed energy deposition
An additive manufacturing process in which focused thermal energy is used to fuse
materials by melting as they are being deposited.
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Thank You !
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