2011.08.29 intro prototyping_methodology

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Prototyping in the design processSummerschool Creative Prototyping 201129.08.2011

Ronald BastiaensBart Grimonprez

Intro | Prototyping | Methodology | Cases

Lets talk about our job first!

A succesfull product = The best solution out af a 1000 ideas. A solution that answers all you customers needs.

For an ordinary person develloping a product is like playing the lottery.And it’s still hard for a designer...

It’s a hell of a job but someone has to do it !-)

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So how can we raise our chances for succes?Google:”productdesign”

Today there are many ways to help, validate, test, measure or speed up your design proces. Creativity tools, Software, Working environments, Online resources, standards...

A major improvement? Good CAD en simulation tools...

Great technology? Rapid prototyping...

How cool is Photoshop, Wacom tablets, 3D studio Max...?

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http://www.google.be/images?q=productdesign&oe=utf-8&rls=org.mozilla:nl:official&client=firefox-a&um=1&ie=UTF-8&source=og&sa=N&hl=nl&tab=wi&biw=1680&bih=857


Some characteristics or downsides to CAD

CAD is cool!

CAD tools are mainly develloped to work accurate and in (very small) detail.

Once you choose a direction... You’ve chosen it!

In CAD there is little room for (vage) concept generation. Detailling in CAD is typical for the final stages of a development process. It’s great for steps that converge towards the final product. It failsin setting up diverging concepts and ideas.

Simulationtools look in detail to one or few solutions, never to different concepts.

Some good “first steps” in using CAD in early design stages.

Still, many companies use only CAD in their design proces, from A to Z

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And what about rapid prototyping?

RP is cool!

For one, it’s not that “rapid” at all.Next day? I want it now!

The oldest RP techniques and the most advanced techniques where only available through service providers. One would only use the for prototypes that had already been through several stages of engineering.

Today some techniques get affordable to buy inhouse. They make it possible to use RP-models earlier in the design process.

Still, you need a 3D model. Still, you are limited by the machines features.

RP is also hype! Some companies buy a machine not knowing what to do with it.

Many companies use prototypes only at the very end of the design proces.

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And what about Photoshop, Wacoms and 3D studio MAX?

3D studio MAX is cool!

Virtual tools for sketching, modelling an visualising are great for exploration.

Still, they only give you a visual input.

Some designers “design” products they’ve never touched, don’t know how to make.

We want our students to materialise their ideas and concepts.

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So how can we raise our chances for succes?

The lack of tools to be used in the early stages of design is painfull.All key decisions are made early in the design proces.

We feel that CAD, simulation, RP and visualisation can help you raise “technical” and “commercial” chances for succes. They can not raise the chance for better design decisions, since they don’t influence early stages of design, since the don’t help you diverse.

If you want to raise you chances on making good design decisions, you need:A good design methodology and tools. (take a look at innowiz.be)Use prototyping (in every meaning of the word) in every stage of your proces.

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We aim at “materialisation”

We use traditional, rapid and virtual prototyping techniques where/when we need them.

Prototypes can be used in any stage of development, varying from quick-and-dirty to high-quality “machined” models. In the early stages one quickly needs many simple, diverging prototypes to explore concepts. Towards the end of development one needs exact models that converge to one design solution. So a choice has to be made between manual techniques, machining, rapid or virtual prototyping. Therefore prototyping needs to be part of an integrated design methodology which can be organized in four stages. During the problem definition stage, prototypes may define boundaries or define possible product interaction. During the idea exploration stage, prototyping serves as a modeling method to concretize fuzzy ideas into tangible objects even involving final users for testing experience prototyping. During the idea selection stage, prototypes may serve as artifacts for user interaction, direct comparison tests, validation and verification. During the communication stage, prototypes are used as tangible life objects that reflect reality better than any other technique. By making prototyping part of the methodology, using it in every stage, one could call this “design by prototyping”.

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So why are we so impressed by a physical model?

Physical prototypes help designers and engineers to better understand the complexity of the design.

They deliver a tangible 3D summary of all involved design issues (shape, function, materials, product personality,…) which gives the designer a chance to solve several problems in one design iteration.

Good prototypes invite to experiment and play with them. They provoke reactions. How you play them is more important than how good the prototypes are.

Prototypes help you think out loud, start conversations. Early prototypes don’t even answer questions, they create new ones.

Designers and customers can move from spec-driven prototypes tot prototype driven specs.

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So why are we so impressed by prototyping?

Prototypes help designers and engineers balance between rationality and intuition. A prototype can help you take a decision that is involves ergonomics, shape, function,

production… at the same time. A decision that can’t be described in parameters. A decision that can’t be simulated by a computer…

A prototype can help you manage the complexity of design. It provides you with constant feedback for all you senses. It’s “real”

Ready? Fire! Aim.

As designers know, a design process is not necessarily a sequential process. Things can happen in parallel. Gathering information, detailing your “set of demands”, generating concepts can happen in parallel. “Design by prototyping”

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Why do most design colleges move towards the virtual?

Because it’s easy?Because it’s sexy?Because it’s efficient?Because that’s what everyone else does?

companies use prototyping more and more every day to validate their designs. They are driven by the need for innovation, the “hype” of rapid prototyping, the need to shorten ‘time to market’,… Therefore companies need designers who can bring their concepts to production.

Does a designer need to know every prototyping techniques?Does he need to know where to look for the right techniques?or…Does he need the attitude to use prototypes in his proces?

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Is prototyping the “holy grale” of product design?Will I be making a prototype in every step of my proces?Will prototyping be the one and only way to succes?

No ! (but this is a prototyping seminar !-)

Prototyping will have to become part of you build-in set of design and creativity techniques and methodology.

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Do companies have many issues concerning prototyping?

Yes !

What do they need to know?Can they outsource it?Will it improve their level of innovation?Will it be expensive?Will their product time-to-market shorten?Do they need an RP machine or do they use their workshop?

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PresentationProtoLab | ActivitiesService: prototypes, maquettes, design,…

Research (FIS, PWO, IWT,…)

Events, seminars, workshops, summerschools


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PresentationProtoLab | InfrastructureVersaLaser lasercutting & engraving

Dimension 3D printer (FDM)

Vacuumcasting Schuëchl

ISEL 3axis CNC milling

Thermoforming 600x500

Traditional workshop metal, wood, plastics, composites

Future investments to come….

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Prototyping techniques | Traditional PrototypingPaper, cardboard, foam, balsa…

Workshop of wood, metal, plastics and ceramics: drilling, sawing, welding, bending…

Composite Laminating: hand lay-up, resin transfer moulding, vacuum & pressure bag forming…

Casting techniques: vacuum casting, investment casting, sand casting, centrifugal casting, rotation moulding…

Thermoforming

CNC milling, lasercutting, electrical discharge machining…

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Workshop of wood, metal, plastics and ceramics: drilling, sawing, welding, bending…



Thermoforming


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Workshop of wood, metal, plastics and ceramics: drilling, sawing, welding, bendin,…



Thermoforming


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Thermoforming


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Thermoforming


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Thermoforming



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Prototyping techniques | Rapid PrototypingWhy?Creating a physical part of a virtual designCreating otherwise impossible forms and shapesCommunication tool for clientsInspecting the technical specs of a designVisual model for marketing purposesSmall series of functional partsMechanical, ergonomical, visual tests


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“The replicator”Prototyping techniques | Rapid Prototyping

Terminology3D printing?Rapid Prototyping?Rapid Manufacturing?Rapid Tooling?e-Manufacturing?Direct Digital Manufacturing?

→ Additive Layer Manufacturing (ALM)


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Prototyping techniques | Rapid PrototypingRapid prototyping = layer manufacturingAdditive technologiesApproximation through STL format (3D)Slicing of the model (2D profiles)Building of the layers


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Prototyping techniques | Rapid PrototypingCatagorisation Rapid PrototypingtechnologiesStarting from liquid resin, to be hardened

Starting from powder, plates or molten polymer

Depending on technology, support structures can be necessary!


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Prototyping techniques | Rapid PrototypingStereolithography (SLA)Developed early 90’sLiquid resinLaser based E.g. 3D-systems, Viper


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Prototyping techniques | Rapid PrototypingStereolithography (SLA)Properties:• Layer thickness: typically 0,1mm• Building material photopolymer• Traditionally hard but fragile material, now also flexible and rigid• Transparant material is possible• Traditionally detoriation under influence of UV• Visual models, mostly not functional (depending on material)• Accurate• Good for finishing• Support and model are the same material


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Prototyping techniques | Rapid PrototypingFused Deposition Modelling (FDM)Thermoplastic based depositionE.g. Stratasys, Fortus family

3D printer variants: Dimension, Uprint


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Prototyping techniques | Rapid PrototypingFused Deposition Modelling (FDM)Properties:• Layer thickness: typically 0,25mm• Materials mostly used: ABS, PC• Limited functional models, verification• Building orientation is important• Accurate• Quick & clean• Smaller models• Break away or soluble support


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Prototyping techniques | Rapid PrototypingSelective Laser Sintering (SLS)Powder and laser based sintering processE.g. 3D-systems, Sinterstation Pro SLS


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Prototyping techniques | Rapid PrototypingSelective Laser Sintering (SLS)Properties:• Layer thickness: typically 0,1mm• Building material PA• Functional models• Lower accuracy• Fairly rough surface• No extra support structure• Appropriate for Rapid Manufacturing


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Prototyping techniques | Rapid Prototyping3D Printing (3DP)Powder and binderInktjet principeE.g. Zcorp, Zprinter450


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Prototyping techniques | Rapid Prototyping3D Printing (3DP)Properties:• Layer thickness: 0,1 - 0,2mm• Building material: plaster powder or starch• Visual models, 3D printing in colour (architecture)• CAD verification• Lower accuracy• Quick & cheap• Fluids for impregnating (hard-flexible)• No extra support structure


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Prototyping techniques | Rapid PrototypingPolyjet Inktjet principeE.g. Objet, Connex Family


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Prototyping techniques | Rapid PrototypingPolyjet Properties:• Layer thickness: down to 16µm• Building material: acrylate• Flexible materials are possible• Semi transparant• CAD verification• Detailed features• High accuracy• Expensive• Support gel to be spouted off


tina.defloo

Afbeelding toevoegen.

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Prototyping techniques | Rapid PrototypingRapid Prototyping/Manufacturing in metal Direct Metal Laser-SinteringSelective Laser MeltingElectron Beam Melting

Full Density

CoCr, Ti, Stainless steel, Al


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Intro | Prototyping | Methodologie | Cases

Prototyping techniques | Virtual PrototypingSketching: Photoshop, Digital Sketch, 3DsMaxModelling: solid of surfaces, constrained, assembly,…Visualisation: 3DsMax, Animatie, Fotoreal,…

Stereoscopical projection: shutter, polarisation, red/blue…3D interactive: Head Mounted Device, spacemouse, Mocap…

CFD: acoustics, streaming, heat transfer, process simulations…FEA: statical forces, analyse, vibrations, wear, non linear material behaviour…Motion Analysis: cinematics, robotics, dynamics…

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Expertise centers:Sirris: www.sirris.beTNO: www.tno.nl

Service:Materialise: www.materialise.comMbproto: www.mbproto.com Layerwise: www.layerwise.comKNS Roeselare / VosschemieZigg Zagg: www.ziggzagg.eu

Mentioned hardware:Dimension: www.dimensionprinting.com Stratasys: www.stratasys.com 3D systems: www.3dsystems.com Zcorp: www.zcorp.com Objet: www.2objet.com

Advised reading, cfr. www.protolab.be/media:Kunstof en Rubber magazine: www.kunststofonline.nl TCT magazine: www.time-compression.com Prototype magazine: www.prototypemagazine.com Marc De Moor, 2009. Werken met innovatieve materialen: Koudhardende kunststoffen. ISBN 9789081490900Gebhardt Andreas,2003. Rapid prototyping. ISBN 3446212590 Chua C.K.; Leong K.F.; Lim C.S.,2003. Rapid prototyping : principles and applications. ISBN 9812381171 Grimm Todd, 2004. User's guide to rapid prototyping. ISBN 0872636976 Hopkinson N.; Hague R.J.M., 2006. Rapid manufacturing : an industrial revolution for the digital age. ISBN 9780470016138 Wohlers Terry T., 2009. Wohlers report 2009 : state of the industry annual worldwide progress report. ISBN 0975442953 Lefteri Chris, 2007. Making it : manufacturing techniques for product design. ISBN 9781856695060

www.protolab.be


http://www.sirris.be/

http://www.tno.nl/

http://www.materialise.com/

http://www.mbproto.com/

http://www.layerwise.com/

http://www.ziggzagg.eu/

http://www.dimensionprinting.com/

http://www.stratasys.com/

http://www.3dsystems.com/

http://www.zcorp.com/

http://www.2objet.com/

http://www.protolab.be/media

http://www.protolab.be/media

http://www.kunststofonline.nl/

http://www.time-compression.com/

http://www.prototypemagazine.com/

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Intro | Prototyping |Methodology | Cases

THE OPTIMAL USE OF PROTOTYPING IN THE PRODUCT DESIGN PROCESS

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Intro | Prototyping |Methodology | Cases

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IDC prototyping| Methodology| Cases

Also…

Vragen?

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Ronald BastiaensBart Grimonprez

HowestIndustrial Design Center | ProtoLabMarksesteenweg 58 8500 Kortrijk

056 24 12 [email protected]@howest.be

2011.08.29 intro prototyping_methodology

Technology

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