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

6. This is a group assignment, only one copy per team should be submitted Where to submit? To the studio locker in TEB on the second floor

7. Prototype definitions A prototype is an original type, form, or instance of something serving as a typical example, basis, or standard for other things of the same category. http://en.wikipedia.org/wiki/Prototype

8. 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

9. Prototype Goals

10. Types of Prototypes 1 Proof-of-Principle Prototype Form Study Prototype Visual Prototype Functional Prototype http://en.wikipedia.org/wiki/Prototype

11. Types of Prototypes 2 Virtual (CAE)  CAD models  Mathematical models  Numerical models Physical  Proof-of-concept  Industrial design  Experimental  Alpha  Beta  Pre-production

12. 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?

14. Mathematical model Vibration of a single degree of freedom system

15. Numerical model Motion of a mechanism

16. Numerical model Modes of vibration of a tuning fork

17. Numerical model Modes of vibration of a pumpkin

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

19. Proof-of-concept Prototypes Demonstrate feasibility Simple construction Often only a part or subsystem Usually not fully functional! Not sufficient for design validation! http://me118.stanford.edu/pictures/Win01Projects/TooShort/images/2nd%20prototype.JPG

20. Industrial Design Prototype How will the product look and feel? Simple materials (foam, wood, etc.) Usually non-functional http://www.linternaute.com/auto/mondial-automobile-concept-car/audi-rsq3.jpg

21. 1962 Prototype of Lunar Module Industrial Design Prototype

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

23. Alpha Prototype Include most but not all functions of the final design Answer questions about overall layout of the design http://drwho.virtadpt.net/pictures/memorial-day-2004/apple-prototype.jpg

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

25. 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 http://www.dpreview.com/articles/canoneos5d/

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

27. Prototype Construction in ES1050 Inexpensive Easy No special tools Quick http://www.ben.com/LEGO/rcx/picoscout/breadboard.jpg

28. Common Prototyping Materials in ES1050 Wood Plastic  Plexiglass Cardboard and paper Metal http://www.riscx.com/pyramac/proto_pics/proto_3_600.jpg

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

30. Construction kits you may want to use in ES1050 Lego Meccano Others http://www.sentex.net/~mwandel/legos/legos.html

31. Lego Many mechanical and electrical parts Inexpensive and easy No tools required http://www.hamster.dk/~purple/robot/iBOT/lego_robot_prototype.jpg http://www.cs.rhul.ac.uk/eca/micromouse/lego/shakey/images/parts.jpg

32. Meccano Uses metal parts Simple tools www.meccano.com http://webperso.easyconnect.fr/esteve.jeanmax/j.e.o/fotopi%E8ces/MarklinPiecP.jpg

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

34. Rapid Prototyping www.zcorp.com

35. Rapid Prototyping

36. Types of prototypes commonly used in ES1050

37. ES050 Prototypes in 2006/2007 when the main Design Project was to “Demonstrate a Scientific Principle”

49. Select the incorrect statement about a prototype ADoes not have to be in the natural size BDoes not have to convey the essential design idea CCan be material or virtual DCan be made using simplified manufacturing processes EDoes not have to look identical as the indented final design