Chapter 10: Concept Prototypes

Proof of process

Production methods and material that can result in desired products

Fault Tree Analysis

symbols used, identify undesirable event (top event) and how it occurs Repeat with occurrence data

Four presentation techniques

Mock up Model Prototype Virtual Prototype

Conceptual Design

Outlines scheme of product, viability of product

Design for X (DFX)

manufacturability, assembly, environment, safety, etc

Design for Manufacturing (DFM)

minimizing cost of production, lower time, and high quality Selection of materials and processes (piece-part and tooling-cost estimates)

Model

physical behavior of system, proof of product prototype

Proof of product

physical embodiment and production feasibility

High Fidelity Prototype

present final product with full functionality and interaction

Virtual prototyping

CAD, feature-based modeling (easy design changes)

Proof of Production

Complete manufacturing process is effective

Four prototype (functional)

1. Proof of concept: initial design 2. Proof of Product: physical embodiment and production feasibility 3. Proof of Process: production methods and materials 4. Proof of Production: complete/effective manufacturing process

FMEA (Failure Mode and Effects Analysis) Steps

1. boundaries and requirements 2. list items 3. identify component and failure modes 4. probability or failure rate for failure modes 5. List effects of failure mode 6. Remarks for failure mode 7. Review/initiate appropriate corrective measures

Focus/outcome of prototype questions

1. who? 2. what features? 3. Dimensions of prototypes 4. horizontal or vertical? 5. low or high fidelity? 6. Resources available?

Design for Environment (DFE)

Disassembly, end of useful life (pollution, energy, resource, quality, recycle)

Categories of prototypes

Domain, Low/High Fidelity, horizontal/vertical

Design for Assembly (DFA)

Ease of assembling final product (low part #, ease of assembly, reduce cost)

Parametric Modeling

FEA, presentation of dimensions as parameters, MANUFACTURING and ANALYSIS stages

FMEA

Failure Mode and Effects Analysis: identify potential failures before they result

Prototype domains

Features Functionality Interaction Design SIMILARITY BETWEEN PROTOTYPE AND PRODUCT

proof of concept

Initial design for future approach

Dimensions of Prototypes

Role Look and Feel Implementation

Types of Models

True: exact geometric responsibility Adequate: test specific characteristics Distorted: violates design condition due to time, $, etc, without result issues

Concurrent Engineering

bringing engineering design and manufacturing personnel together early in the design phase

Low Fidelity Prototypes

built from available or waste resources limited functionality/features/interaction

Prototype

comprehensive prototype (beta)

Mock-up

feel for design, proof of concept prototype

Horizontal Prototype

includes all features with limited functionality

Vertical Prototype

includes limited features with all functionality