1. Creating a Prototype Engineering Design and Development
© 2013 Project Lead The Way, Inc.

2. Prototypes Why Create a Prototype? Mock-Up /Presentation Prototype
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Prototypes
Why Create a Prototype?
Mock-Up /Presentation Prototype
Functioning Prototype
Examples of EDD Prototypes
Image: This is a picture of an EDD project prototype – the “Sip and Drip”. The design was a proposed solution to the problem of ice cream cones dripping, breaking, and creating a mess.
Sip and Drip

3. Why Create a Prototype?
If a picture is worth a thousand words, how much is a prototype worth?
Identify flaws, inefficiencies, and design alternatives
Gauge reactions from potential customers, buyers, or investors

4. What aspects of form, fit, and function are important to your design?
Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Form, Fit, and Function
Physical, functional, and performance characteristics or specifications that uniquely identify a component or device and determine its interchangeability in a system
Form: The shape, size, mass, weight, and other visual parameters which uniquely characterize an item.
Fit: The ability of an item to physically interface or interconnect with or become an integral part of another system.
Function: The action or actions that an item is designed to perform.
These characteristics may not apply to all prototypes, but form, fit, and function should be considered when developing a prototype.
Image: This EDD project is called the Fertigator. It was designed to water and fertilize residential plants. It utilized a tube with small holes that extended to the root zone of the plants and a removable cap into which a fertilizer capsule could be placed.
Fertigator
What aspects of form, fit, and function are important to your design?

5. Mock-Up/Presentation Prototype
Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Mock-Up/Presentation Prototype
A three-dimensional representation of your invention that offers greater visual impact than a drawing would provide.
What form, fit, and function questions can be answered with a presentation prototype?
A mock-up or presentation prototype will generally provide an accurate visual representation but will not function to the full extent of the actual product. In most cases a mock-up is constructed of material(s) other than those specified and may not be constructed within the specified tolerances.
Answers to the question vary based upon the presentation prototype being created, but it should be discussed and considered. The more questions that are answered by the model, the better the prototype.
Images courtesy of Dimension

6. Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Functional Prototype
A model intended to finalize the operational elements of your invention before it goes into production.
Types of Functioning Prototypes
Full Scale Working Model
Scaled Working Model
Partial Model
Virtual Model
You should be able to assess the function of a design using a functional prototype. Many functional prototypes, however, may not look like the envisioned finished product. This is why, in many cases, it is important to have a presentation prototype as well.
Full scale working model
Scaled working model: The model may be smaller or larger than the envisioned final version.
Partial model: A partial model is one in which only the parts necessary to demonstrate a particular concept or function are built and assembled. For example, you would not need to build an entire car to demonstrate the concept of turn signals.
Virtual model: A virtual model is one that exists only in software. As computers become more and more sophisticated, it is becoming more common to demonstrate a problem’s proposed solution virtually using a computer.
What form, fit, and function questions can be answered with a functioning prototype?

7. Design Process Prototypes Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Where are you in the design process?
[click] You’re finally at the stage at which you will build your design.

8. Rule of Thirds Research and Exploration Design and Construction
Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Rule of Thirds
Research and Exploration
Design and Construction
Testing, Documentation, and Presentation
Problem Selection
Design Specification
Testing Criteria & Method
Topic Background
Decision Matrix
Testing Procedure
Problem Statement
Concept Testing
Physical Testing
Statement of Purpose
Design Proposal
Record Data
Cited Validation
Gantt Chart (timeline)
Critical Design Review
Cited Justification
Sketching Refinement
Redesign and Refine
Past & Present Solutions
Technical Drawing
Re-test
Market Research
Material List
Determine Conclusion
Problem Proposal
Cost
Multimedia Display
Tool Selection
Web Page
Tool Safety
Research Paper
Mock Up & Modeling
Electronic Portfolio
Prototype Construction
In working toward actually building your design, you will carefully plan the construction of your prototype. This will include creating technical drawings and planning the use of resources that you will need. In addition to other considerations, you will create a bill of materials, estimate cost, plan your use of tools and equipment, and consider what additional knowledge you will need in order to improve your product and construct a good prototype. When all the planning is complete, you will be well prepared to construct your prototype.
[click] When construction is complete, you will be at the end of the middle third of the Design Process.
Prototype Construction

9. Examples of EDD Problems
Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Examples of EDD Problems
Garage Door Notification System
Car Visor Stop Light Assist
Car Visor Stop Light Assist – When a car is stopped at a traffic light and the car is facing directly into the sun at certain times of the day, it is difficult to see which lamp is illuminated in the traffic light (red, yellow, or green). This visor has a camera and LED screen that allows the driver to see a stoplight when the sun is directly behind (for instance, when a driver is facing west at sunset).
Garage Door Notification System – Many people drive away from home and do not remember whether they closed their garage door. Many accidentally leave a garage door opened overnight. This system sends you a text message if your garage door is left open longer than 20 minutes.
Practice Pitch Return – It is sometimes difficult for pitchers to find a partner with which to practice pitching. Many catchers do not like to help pitchers practice because it is tough on their knees and they want to spend their time at batting practice. This device allows a baseball/softball pitcher to practice throwing strikes without requiring a catcher to return the ball. What makes this device particularly unique is the ability to switch from baseballs to softballs.
Small Bore Air Rifle Target Changer – Remote target changers and remote position changers currently exist. However, no device is available that does both. This device allows a target shooter to change targets as well as the position of targets remotely.
Visible Toaster – The level of “doneness” indicated on many toasters is arbitrary and non-descriptive. It is often difficult to determine how brown a bagel or piece of bread is while hidden within a toaster, which often results in under- or over-toasting. The Visible Toaster Design allows the user to monitor the darkness of the toast as it is toasting.
Small Bore Air Rifle Target Changer
Visible Toaster
Practice Pitch Return

10. Examples of EDD Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Examples of EDD Prototypes
Improved Marching Band Music Holder
Utili-Tool
Snow Blower Clog Remover
Utili-Tool – this product was designed to unclog the chute of a snow blower after it becomes clogged with snow and ice during use. The Utili-tool includes a chuck on the front onto into which various tools (such as an auger or brush) could be fit and then rotated at high speed to dislodge the clog. Here the students are using a torque meter to measure the torque (in foot-pounds) that their design generated.
Forearm Workout Device – this product was designed to attach to any weight bar. It worked out the forearms while doing other lifts.
Portable Basketball System
Portion Control Calculator
Forearm Workout Device

11. Examples of EDD Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Examples of EDD Prototypes
Cross Country Training Ski
RFDI Tag Controlled Light
Cross Country Training Ski – This training ski provides more effective training by better mimicking the motion of cross country skiing.
RFDI Tag Controlled Light – This product is designed to deter people without handicapped parking permits from parking in handicapped parking spaces. A computer chip (intended to be activated by the Department of Motor Vehicles) would be embedded in the handicapped parking tag that hangs from rearview mirrors in vehicles. A device on the handicapped traffic sign would receive the signal and flash a light when a valid tag is within range.
Better Garbage Disposal – Students worked with a GE employee (who holds several patents) to develop a kitchen sink garbage disposal that wouldn’t jam when larger solid food wastes (such as chicken bones) were inserted.
Snowplow-Proof Mail Box – This design allows the mailbox to swing up and around, if it is hit by a vehicle. The mailbox automatically returns to the main position.
Better Garbage Disposal
Snowplow-Proof Mail Box

12. Examples of EDD Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Examples of EDD Prototypes
Hands Free Lighting Device (left) with Circuit and FDM (fused deposition model) (above)
Boat Hull Cleaner
Automatic Watering System (for indoor plants)
Tubeless Non-Flattening Tire
Temperature Sensing,
Self-Regulating Blinds

13. Examples of EDD Prototypes
Engineering Design and Development
Lesson 4.1 Plan for the Prototype
Examples of EDD Prototypes
Touch Screen Order Entry System
Touch Screen Order Entry System for fast food drive through windows – This system allows direct entry of an order and is designed to eliminate order errors by an order taker. It allows for additions and holds and keeps a running total of the order. The students used Lab View to create the program. This order error problem was suggested by a small independent company that is currently using the system at two stores.
Dog Self-Exercising Machine for high energy pets – This device launches a tennis ball. Once the dog retrieves the ball, the device allows the dog (once trained) to reload and re-launch the ball without human intervention.
Electrolysis Devices – These devices are designed to produce hydrogen, for hydrogen fuel cells, through electrolysis of water. Water is contained between two polycarbonate sheets, with a metal plate in the middle. A current is passed through the metal plate and the hydrogen and oxygen are drawn off with the tubes.
Dog Self-Exercising Machine
Electrolysis Devices

14. Prototypes Why Create a Prototype? Mock-Up/Presentation Prototype
Functioning Prototype
Examples of EDD Prototypes

15. Image Resources
Dimension Printing – Thanks to EDD teachers who shared images of student prototypes