Virtual Prototyping & Rapid Prototyping

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<p>Developing Products That Will Perform</p> <p>Virtual Prototyping &amp; Rapid PrototypingJonathan Prince &amp; Greg Morehouse1What are we talking about?What is Virtual Prototyping from an engineering perspective?Simulation of Rapid Prototypes Why perform Virtual Prototyping and Rapid Prototyping?Time to marketAccuracy of designRisk mitigationVirtual Prototyping Process - Bogie Case Study!2Quick outline of the Agenda</p> <p>Look at the design The Design process Primarily at the Front End Key to getting the project rightI talk primarily about Product design Many of the same principles apply to machine design or project work i.e.:Clearly identifying scope, having stage gates and having the right culture</p> <p>J. PrinceIm currently a Business development Manager for Motovated Design Services and own my own Start up The Ideas FoundryEngineer - Started on the tools and did a Trade, NZCE and BEPrivileged to have worked for some of NZs best design companies in Tait Electronics, Formway Furniture, InFact &amp; Motovated Great experience in taking Kiwi designed product to the International marketHeld roles from Fitting &amp; Turning, Design, Project Management,, Business Development &amp; Sales, Snr Management rolesTait Electronics- Design Authority on $50 Mill Handheld lineFormway Project leader on the award winning LIFE chair and looked at how/ where they could leverage their IPInFact Engineering Management &amp; Business DevelopmentRight Connect - CEO taking Right Hemisphere product to Asia Pacific</p> <p>VIRTUAL PROTOTYPINGTypes of Virtual PrototypingStress (Structural) Analysis (FEA)Understand the effects of possible loads and restraints earlyRemove unnecessary weight &amp; materialFlow Analysis (CFD)Fluid flow, losses, flow lines, heat transfer, turbulenceCoupled Fluid / Structural Interaction (FSI)Mold Flow AnalysisWill the mould fill?Will the part last?Computer Aided Machining (CAM)Can the mold / part be made?!Risk Mitigation Get it right for final (productionised) prototyping!</p> <p>33EMBRACE TECHNOLOGYDumbfounding how many NZ Eng companies dont utilise technology- Use Chalk on Floor example hereCAD many still working in 2DRapid prototyping The ability to turn around ideas overnightFEA Test your designs on the fly minimise need for expensive time consuming prototypesData management Reuse existing designs, create precise BOMs/ cut lists, Expedite Documentation requirements, Accurate variant control3D Interactive collaboration softwareACCURATE PRODUCT &amp; MATERIAL QUOTESAccurate BOMs &amp; Product &amp; Material quotesCREATION OF PRODUCT VARIANTS Documentation/ version controlDESIGN OF JIGS &amp; FIXTURESAccurately place components for fitting/ holding/ weldingEXPORT TO CNCGeneration of cutting paths off cad model</p> <p>USE OF MODELS FOR MARKETING MATERIALNot necessarily high on Engineers radar but huge time/ cost savings opportunities hereVery quick, easy and accurate models for marketing material/ Technical papers/ Spec sheets/ etcSaves huge time and cost involved in creation and photographing of 1st Off samplesPicturing and reviewing motion - animationRendering/ demosExploded views</p> <p>DESIGN FOR SUSTAINABILITY - Discuss LIFE chair &amp; Aust Govt contracts Not only key to ensuring that we can continue to exist on this planet but very good economic senseStill a competative advantage but wont remain that way for long wil become manditoryProduct must be well designed, fit for purpose, customer centred.AND SustainableSustainability makes for vey smart business pratise!!Concentrate on 3 RsUnderstanding the layered build processUnderstanding the difference in material properties - strength, ductility &amp; stiffnessIsotropic, Orthotropic vs. Anisotropic?Non-Linear materials propertiesSimulating fatigueSimulating creepPitfalls for the uninitiated!</p> <p>RAPID PROTOTYPING STRUCTURAL SIMULATIONEspecially for Additive Manufacture!What is VP and Why use it?!</p> <p>1. Understanding the build process, fits and tolerances. Do the components go together, will the work together well, is it repeatable?</p> <p>2. Simulating loads, heat, electrical stress, flow,?</p> <p>Long term stress &amp; loading scenarios of time</p> <p>Moldflow, CAM software</p> <p> How does something get built on the production line, utilising the likes of Deep Exploration with full 3d working instructions and collaboration tools</p> <p>4RAPID PROTOTYPINGDo some Simulations!BenefitsIssuesShort fallsPitfalls for the uninitiated</p> <p>VIRTUAL PROTOTYPING?Nah, Ill just whip one up!</p> <p>http://www.3ders.org/articles/20121204-tested-3d-printed-gun-breaks-within-6-shot.html66EMBRACE TECHNOLOGYDumbfounding how many NZ Eng companies dont utilise technology- Use Chalk on Floor example hereCAD many still working in 2DRapid prototyping The ability to turn around ideas overnightFEA Test your designs on the fly minimise need for expensive time consuming prototypesData management Reuse existing designs, create precise BOMs/ cut lists, Expedite Documentation requirements, Accurate variant control3D Interactive collaboration softwareACCURATE PRODUCT &amp; MATERIAL QUOTESAccurate BOMs &amp; Product &amp; Material quotesCREATION OF PRODUCT VARIANTS Documentation/ version controlDESIGN OF JIGS &amp; FIXTURESAccurately place components for fitting/ holding/ weldingEXPORT TO CNCGeneration of cutting paths off cad model</p> <p>USE OF MODELS FOR MARKETING MATERIALNot necessarily high on Engineers radar but huge time/ cost savings opportunities hereVery quick, easy and accurate models for marketing material/ Technical papers/ Spec sheets/ etcSaves huge time and cost involved in creation and photographing of 1st Off samplesPicturing and reviewing motion - animationRendering/ demosExploded views</p> <p>DESIGN FOR SUSTAINABILITY - Discuss LIFE chair &amp; Aust Govt contracts Not only key to ensuring that we can continue to exist on this planet but very good economic senseStill a competative advantage but wont remain that way for long wil become manditoryProduct must be well designed, fit for purpose, customer centred.AND SustainableSustainability makes for vey smart business pratise!!Concentrate on 3 Rs</p> <p>RAPID PROTOTYPING SIMULATIONEspecially for Additive Manufacture!7VIRTUAL PROTOTYPING &amp; RAPID PROTOTYPINGWhy are they important?Time to marketCrucial to product profitability</p> <p>Accuracy of designCrucial to the brand, the product and success of the company</p> <p>Mitigating riskWhat will it cost if you get it wrong?8RAPID PROTOTYPINGTensile Strength Optimisation</p> <p>From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/</p> <p>Part and material properties in selective laser melting of metals</p> <p>Jean-Pierre.Kruth@mech.kuleuven.beRAPID PROTOTYPINGTechniques</p> <p>From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/RAPID PROTOTYPINGUnexpected Results!</p> <p>From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/RAPID PROTOTYPINGAdditive Manufacturing RisksFrom: Thinking ahead the Future of Additive Manufacturing Analysis of Promising Industries</p> <p>Why is virtual prototyping important?Mitigating riskwww.latimes.com13Risk: The probability of something happening multiplied by the resulting cost ($$ or life) if it does.Risky? Really?!Discuss Analysis may be used to optimise products, to guide design decisions, and may be required by regulation for some items. One of the key uses of analysis is to reduce risk and uncertainty.</p> <p>To evaluate how much analysis a client needs, we often ask the following questions: have a think about your own experience as I go through these:How many products will be produced?What is the dollar value of the product?Where will they be produced and sold?What damage to your brand, profit or life could a product failure result in?</p> <p>With the KiwiRail project, the evaluated risk was high the smallest failure could result in a massive loss of $ and lie. The engineering effort was correspondingly high. We try to match the amount of analysis to the degree of risk and for most products this is usually only a couple of days analysis, for a huge gain in confidence and peace of mind for our clients.</p> <p>14RAPID PROTOTYPINGPitfalls</p> <p>The main disadvantage of prototyping can be summed up in one complaint that is easy to imagine: it has a tendency to encourage informal design methods which may introduce more problems than they eliminate.This failure can be avoided if the following issues are kept in mind:Prototyping can lead to a design-by-repair philosophy, which is only an excuse for lack of discipline. Prototyping does not eliminate the need for front-end analysis. It cannot help if the situation is not amenable to instructional design. A prototype cannot substitute completely for a paper analysis. There may be many instructional design problems which are not addressed bv prototyping. Prototyping may lead to premature commitment to a design if it is not remembered that a design is only a hypothesis. When prototyping an instructional package, creeping featurism (the adding of bells and whistles) may lead to designs that get out of control." </p> <p>15ToyotaKey points from the article</p> <p>Why is virtual and rapid prototyping important?Accuracy of Design17Fit for Purpose?Do things Fit?Design Intent: Do they work as intended?Can it take the loads?What are the loads, how is it used and restrained?Can it handle the environmental conditions?What are the long term, ongoing scenarios?How might this be used &amp; abused?Rubbish in = rubbish2 out </p> <p>Is it Fit for Purpose?</p> <p>What is the purpose?!18Case study: Life changing!</p> <p>19Using simulationCase studyUsing simulation in prototyped products (heart) tbc</p> <p>Case study: Lucky?!$1/4M prototype25 Year life 10 Million cycles3 month test cycle2121EMBRACE TECHNOLOGYDumbfounding how many NZ Eng companies dont utilise technology- Use Chalk on Floor example hereCAD many still working in 2DRapid prototyping The ability to turn around ideas overnightFEA Test your designs on the fly minimise need for expensive time consuming prototypesData management Reuse existing designs, create precise BOMs/ cut lists, Expedite Documentation requirements, Accurate variant control3D Interactive collaboration softwareACCURATE PRODUCT &amp; MATERIAL QUOTESAccurate BOMs &amp; Product &amp; Material quotesCREATION OF PRODUCT VARIANTS Documentation/ version controlDESIGN OF JIGS &amp; FIXTURESAccurately place components for fitting/ holding/ weldingEXPORT TO CNCGeneration of cutting paths off cad model</p> <p>USE OF MODELS FOR MARKETING MATERIALNot necessarily high on Engineers radar but huge time/ cost savings opportunities hereVery quick, easy and accurate models for marketing material/ Technical papers/ Spec sheets/ etcSaves huge time and cost involved in creation and photographing of 1st Off samplesPicturing and reviewing motion - animationRendering/ demosExploded views</p> <p>DESIGN FOR SUSTAINABILITY - Discuss LIFE chair &amp; Aust Govt contracts Not only key to ensuring that we can continue to exist on this planet but very good economic senseStill a competative advantage but wont remain that way for long wil become manditoryProduct must be well designed, fit for purpose, customer centred.AND SustainableSustainability makes for vey smart business pratise!!Concentrate on 3 RsAnalysis processProgressive</p> <p>Never been done before in NZ Very collaborative effortNZ Narrow gauge Was based on another design but basically had to start againDiscuss how we started with:An analysis plan, Hand calcs etc and Progressively increased the level of analysis as the project progressed22Analysis processProgressiveConservative</p> <p>railpictures.net image phil cotterillWe never know where these things end up and how theyre usedDiscuss adding enough margin upfront assisted with as-built changesLast thing we want is a death no our hands23Analysis processProgressiveConservativeControlled</p> <p>Discuss Scheduled Peer reviewsChecking proceduresBenefit of analyst completing the drawingsTest reviewBuild review24Analysis processProgressiveConservativeControlledValidated</p> <p>AS mentioned, fantastic project and got it right first timeDiscuss virtual physical testingSimulate 30 years of track25Case study: Lucky?!$1/4M prototype25 Year life 10 Million cycles3 month test cycle</p> <p>Right first time!</p> <p>Get it right, before you cut steel!2626EMBRACE TECHNOLOGYDumbfounding how many NZ Eng companies dont utilise technology- Use Chalk on Floor example hereCAD many still working in 2DRapid prototyping The ability to turn around ideas overnightFEA Test your designs on the fly minimise need for expensive time consuming prototypesData management Reuse existing designs, create precise BOMs/ cut lists, Expedite Documentation requirements, Accurate variant control3D Interactive collaboration softwareACCURATE PRODUCT &amp; MATERIAL QUOTESAccurate BOMs &amp; Product &amp; Material quotesCREATION OF PRODUCT VARIANTS Documentation/ version controlDESIGN OF JIGS &amp; FIXTURESAccurately place components for fitting/ holding/ weldingEXPORT TO CNCGeneration of cutting paths off cad model</p> <p>USE OF MODELS FOR MARKETING MATERIALNot necessarily high on Engineers radar but huge time/ cost savings opportunities hereVery quick, easy and accurate models for marketing material/ Technical papers/ Spec sheets/ etcSaves huge time and cost involved in creation and photographing of 1st Off samplesPicturing and reviewing motion - animationRendering/ demosExploded views</p> <p>DESIGN FOR SUSTAINABILITY - Discuss LIFE chair &amp; Aust Govt contracts Not only key to ensuring that we can continue to exist on this planet but very good economic senseStill a competative advantage but wont remain that way for long wil become manditoryProduct must be well designed, fit for purpose, customer centred.AND SustainableSustainability makes for vey smart business pratise!!Concentrate on 3 Rs</p> <p>Design without analysis is like pilots without instruments; they know theyre flying, but they might not know exactly where they are!Over the Top?27SummaryBuild virtual prototyping and rapid prototyping into your development process!Dont skimp on the engineeringRubbish in = rubbish2 out Develop a virtual prototyping methodologyGet it right before you cut steel or inject plastic!28Key Things I want you to take out of this:If youre going to develop product, implement a good Development ProcessDo your research !!3. Create a culture that nurtures Innovation &amp; embrace technologyEmbrace TechnologyDevelop value add product</p> <p>High level review of whats been talked about with focus on how 3D CAD benefits the 4 Key points:Improving InnovationReducing Time to MarketReducing Development CostImproving QualityFocus on the Bottom Line</p> <p>Discuss:Issues associated with a poor processBenefits of a Robust ProcessStages involved in a Robust ProcessThe power of 3D CAD in that process</p>

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