1. Prototyping Integrated Product and Process Design ME 475 | 2011-2012

2. Creativity Dilbert Style

3. 3

4. Class Logistics Peer reviews etc. = 2% points overall Individual contribution multipliers If everybody is working equally, and team gets an A, all members get an A All members can’t get A if team grade is B. Average must be 1.0 or less; we’ll adjust it if it’s not Individual Assignment 2 Evaluate your team’s work on concept generation and evaluation 4

5. Individual Contribution Multipliers

6. Build and Test Models and Protos u6u6 Perform Economic Analysis Benchmark Competitive Products Build and Test Models and Prototypes Identify Customer Needs Establish Target Specifications Generate Product Concepts Select Product Concept(s) Set Final Specifications Plan Downstream Development Test Product Concept(s) Development Plan

7. Things to Think About What is a prototype? Why do we use them? What are the different kinds of prototypes? How do we plan for prototypes? What resources are available to us for making prototypes?

8. Quiz: Closed book 1 minute as an individual; then 2 minutes as a team. Team scores will be reported. 1. A prototype is ___________________ of a product along _____________________. In the text, prototypes are classified along two axes. 2. One axis is from _____________ to _____________________. 3. The other axis is from _________________ to _________________. 6 points possible; one point per blank.

9. What is a Prototype? A prototype is an approximation of the part or product along one or more dimensions of interest. For the creation of the hand-held computing paradigm and the creation of the first commercially successful example of a hand-held computing device.

10. Types of Prototypes Note: The text considers math models of a product to be a kind of prototype

11. A Needle in the Haystack

12. Why Make Prototypes? Prototypes are used in product development for: 1.Learning (to answer questions or gain experience); “how does it work”, “what affects its performance”, “does it fit”, “can it withstand the loading conditions”? 2.Communicating an idea or concept 3.Integrating components and subsystems to make sure they work together as expected 4.Demonstrating product development milestones (that the product has reached a desired level of functionality/usability/desired aesthetics) 5.Push the project along – prototypes can be goals that focus efforts

13. Kinematics Analysis How do we Know it Works? Motion Simulations Finite Element Analyses Evaluation of Various Prototypes 12 3 4 5

14. Prototyping Principles to Consider Analytical prototypes are more flexible than physical prototypes Physical prototypes are required to detect unanticipated phenomena Prototypes reduce the risk of costly iterations Prototypes expedite other development tests

15. How to Plan a Prototype A four-step prototype planning process: 1.Define the Purpose of the Prototype What question are we trying to answer? 2.Establish the level of approximation of the prototype 3.Outline an experimental plan 4.Create a schedule for procurement, construction, and testing

16. Level of Approximation - Low fidelity model - Low computational cost - High fidelity model - High computational cost

17. Simple models can be your friends Don’t ignore the benefits of simple approximations Reference books have solved models for common cases Machine design handbooks Roark’s formulas for stress and strain Answers may be good enough to proceed

18. How to Plan a Prototype

19. Team Exercise Identify three important questions about one of your top concepts For each of these questions, identify the following: an analytical prototype that could be used to help answer the question a physical prototype that could be used to help answer the question

20. Series of Prototypes

21. How do we plan for a series of Prototypes? A few quick mock-ups to help select final concept Multiple prototypes (and multiple types of prototypes) to take your work from concept to final design Milestone prototypes at the end of semester 1. Final prototype, that shows the full function of your product/process (at end of semester 2)

22. POC Hardware: Ink Jet Cartridge De-taper Device must remove tape placed over ink cartridge nozzles

23. De-taper Prototype 1

24. De-taper Prototype 2

25. De-taper Prototype 3

26. De-taper Final Design

27. Pistachio Feeder

28. Pistachio Prototypes

29. Pistachio Prototype

30. Pistachio Final Design

32. Dangers of Prototyping “Hardware swamp” All the efforts are going in to making the prototype work, rather than working on the design. If you can’t readily make it work in the lab as a prototype, the chances it will work in the real world are very small. Follow your plan!

33. What is available to you? 33 Physical Analytical Ken’s Machine Shop (150 CB) Rapid Prototyping Lab (Perry Carter (422-2901)) Composites Lab Tooling Lab (155 CTB) PRL(SW of smoke stack) Laser Cutter CNC Router Film Cutter Precision Machining Lab (108 CTB) Kevin Cole & Checkout Room Finite Element Analysis Motion Simulation Tolerance Simulation Solid CAD Modeling Governing Relationships (previous classes) Technical Computing (matlab, etc)

34. Resources for POC and Design To find ideas for concept generation To find out what is on the market for purchase To obtain parts for Proof of Concept (POC) To order components for final designs

35. Review Reduce risk by proving with multiple avenues that your designs will work Physical and analytical prototypes can help Have a purpose for a prototype before you make it Use a series of prototypes to support your product development efforts

36. Another Series

37. 37 Rapid Prototyping (RP) Layer-by-layer fabrication of 3D physical models from CAD Data. (note that these methods are additive, not subtractive) RP Systems join liquid, powder, sheet materials to form complex parts. RP Systems fabricate plastic, wood, ceramic, and metal objects. “Rapid” means 1 hour to 3-4 days, compared to days or weeks for subtractive approaches. Began in 1986 when Stereolithography process was patented.

38. 38 Rapid Prototyping Process 1.Create the CAD Model 2.Convert the CAD Model to data exchange format 3.Slice the STL File into thin cross-sectional layers 4.Layer-by-Layer Construction 5.Cleaning and Post-processing

39. 39 Stereolithography (SLA)

40. 40 SLA Video sla.avi

41. Watch Your Units!

42. 42 Fused Deposition Modeling (FDM)

43. 43 FDM Video fdm.avi

44. Example - MSC

45. Example - Newark

46. Example - McMaster

48. Prove, with two different methods, that your designs will work as expected!!! He’s Crazy! Why do that?

49. A Simple Example Prove that your assembly of 39 parts has the proper interferences and clearances. Solid CAD Model Prototype Model

50. Another Example Strain Energy Model Finite Element Model

51. An Important Connection Physical Prototype, Mock-Up, Proof of Concept Hardware Digital prototype, Digital mock-up, Virtual prototype Predictive math model, physics model Analytical Prototypes Digital prototype, Digital mock-up, Virtual prototype