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Concept
Development
System-Level
Design
Detail
Design
Testing and
Refinement
Production
Ramp-Up
Identify
Customer
Needs
Establish
Target
Specifications
Generate
Product
Concepts
Select
Product
Concept(s)
Test
Product
Concept(s)
Set
Final
Specifications
Plan
Downstream
Development
Development
Plan
Prototyping Example:
Apple PowerBook Duo Trackball
Outline
Definition
Steps in prototyping decisions
Purposes of prototypes
Principles for choosing a prototype type
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Definition
An approximation of the product
along one or more dimensions of
interest.
Physical prototypes vs. analytical
prototypes
Comprehensive (with all the
attributes of a product) vs. focused
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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
alpha
beta
prototype prototype
ball
support
prototype
final
product
trackball mechanism
linked to circuit
simulation
Comprehensive
Focused
simulation
of trackball
circuits
equations
modeling ball
supports
not
generally
feasible
Analytical
Focused physical
Learning and communication
Comprehensive physical
Learning, communication, integration, and
milestones.
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Prototype decision
(technical risk vs. prototype cost)
Low risk- low cost (e.g., printed matters)
No need for comprehensive prototypes
Low risk high cost (ships, buildings)
Cant afford comprehensive prototype.
High risk low cost (software)
Many comprehensive prototypes
High risk high cost (airplanes, satellites)
Use analytical models extensively
Carefully planned comprehensive prototypes
Sell the first unit
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Physical Prototypes
Tangible approximation of
the product.
May exhibit unmodeled
behavior.
Some behavior may be an
artifact of the
approximation.
Often best for
communication.
Analytical Prototypes
Mathematical model of the
product.
Can only exhibit behavior
arising from explicitly
modeled phenomena.
(However, behavior is not
always anticipated.
Some behavior may be an
artifact of the analytical
method.
Often allow more
experimental freedom than
physical models.
Comprehensive Prototypes
Implement many or all
attributes of the product.
Offer opportunities for
rigorous testing.
Often best for milestones
and integration.
required
to
detect
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Some comprehensive
prototypes build (and sold?).
Few or no comprehensive
prototypes are built.
High
Many comprehensive
prototypes are built.
Low
Comprehensive Prototypes
Low
High
Cost of Comprehensive Prototype
Prototyping Strategy
Prototype technologies
Traditional prototyping methods
3D computer modeling
Free-form fabrication
Stereolithography
Using various materials including wax, resin, paper,
ceramics, and metals.
Lamination
Using paper cut, lay by layer
Rapid prototyping
Laser curing (solidifying) soft materials such as resin, layer
by layer
3D printing
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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...
Other Images
Prototyping
Chapter 12
EIN 6392, Product Design
summer 2012
Steps
Define the purpose of the prototype
Establish the level of approximation of the
prototype
Outline an experimental plan
Create a schedule for procurement,
construction, and test
Plan milestones for prototypes (alpha, beta,
pre-production)
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