ES1050 – Introductory Engineering Design and Innovation Studio Models and Prototypes Prof. Paul Kurowski

Prototype definitions

Models and Prototypes Abstractions and simplifications of final design as needed to demonstrate, test and refine a design Physical prototypes are needed to demonstrate, test and refine a design

Prototype Goals

Types of Models/Prototypes Virtual (CAE)  CAD models  Mathematical models  Numerical models Physical  Proof-of-concept  Industrial design  Experimental  Alpha  Beta  Pre-production

DESIGN PROTOTYPING TESTING PRODUCTION CAD PROTOTYPING TESTING PRODUCTION CAE FEA Windows OS solid CAD TRADITIONAL PRODUCT DESIGN PROCESS SIMULATION DRIVEN PRODUCT DESIGN PROCESS affordable computers CAE tools are implemented to move design iterations from physical prototypes to virtual space of numerical (computer) models Why CAE?

Mathematical model Vibration of a single degree of freedom system

Numerical model Modes of vibration of a bracket

Types of Models/Prototypes Virtual (CAE)  CAD models  Mathematical models  Numerical models Physical  Proof-of-concept  Industrial design  Experimental  Alpha  Beta  Pre-production

Proof-of-concept Prototypes Demonstrate feasibility Simple construction Often only a part or subsystem Usually not fully functional! Not sufficient for design validation!

Industrial Design Prototype How will the product look and feel? Simple materials (foam, wood, etc.) Usually non-functional

1962 Prototype of Lunar Module Industrial Design Prototype

1969 Lunar Module

Experimental Prototype Intended for physical experiments and testing Often only a subsystem Prototype of shock-absorbing caster Test results

Alpha Prototype Include most but not all functions of the final design Answer questions about overall layout of the design

Beta Prototype Fully functional prototype Final product form Purpose is final testing Different manufacturing processes used  Machining rather than injection molding  Made by hand

Pre-Production Prototype Made using final production processes and tooling Identical to the final product Used to fine-tune the production process Pre-production Prototype

Prototype Goals Answer simple questions (e.g. will an idea work?) Obtain feedback from customers Aid in visualization Realistic models for marketing and advertising Study the “look and feel” of the product Functional testing and evaluation

Prototype Construction in ES1050 Inexpensive Easy No special tools Quick

Common Prototyping Materials in ES1050 Wood Plastic  Plexiglass Cardboard and paper Metal

Prototyping Tools in ES1050 Simple hand tools  Scissors  Screwdrivers  Wrenches Simple joining methods  Glue  Duct tape  Screws

Construction kits you may want to use in ES1050 Lego Meccano Others

Lego Many mechanical and electrical parts Inexpensive and easy No tools required

Meccano Uses metal parts Simple tools

Rapid Prototyping is available to ES1050 Creates a physical prototype directly from a CAD model Can include color Uses low-strength materials

Rapid Prototyping

Rapid Prototyping

Types of prototypes commonly used in ES1050

ES050 Prototypes in 2006/2007 when the main Design Project was: Demonstrate a Scientific Principle