4 Advice to Choose a Rapid Prototyping

Definitions

Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.

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Concept Model: a physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.

Prototyping Attributes
Speed: turnaround time to convert a computer file into a physical prototype

Appearance: any visual attribute: color, texture, size, shape, etc. 

Assembly/Fit Testing: making some or all of the parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. spacing and the mating slots at 1 in. spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.

Prototyping Attributes
Form: the shape of the part: features and size

Fit: how the part mates with other parts

Functional Testing: seeing how a part or assembly will function when subjected to stresses representing what it will see in its actual application.

Prototyping Attributes
Chemical Resistance: resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.

Mechanical Properties: strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.

Electrical Properties: interaction of electrical fields and the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistance, static decay, etc.

Thermal Properties: changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, vicat softening point, etc.

Optical Properties: ability to transmit light. May include refractive index, transmittance, and haze.

Life Testing: testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV, etc.) to estimate in a shorter period of time, how the product will react over its expected life.

Prototyping Attributes
Mechanical Properties (fatigue strength): ability to withstand large numbers of load cycles at various stress levels.

Aging Properties (UV, creep): ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.

Regulatory Testing: testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as medical, food service or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).

Prototyping Attributes
Flammability Properties: the resistance of a resin or part to ignition in the presence of a flame.

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EMI/RFI Properties: the ability of a resin, part or assembly to shield or block Electromagnetic Interference or Radio Frequency Interference.

Food Rating: approval of a resin or part to be used in applications where it will come in contact with food while it is being prepared, served or consumed.

Biocompatibility: the ability of the resin or part to be in contact with human or animal bodies, outside or inside the body, without causing undue adverse effects (e.g., irritations, blood interactions, toxicity, etc). Biocompatibility is important for surgical instruments and many medical devices.

Summary

Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.

What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability.&#;

If your prototype can faithfully represent the attributes of the end-product, it is by definition functional.&#;These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.

If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable.&#;These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can&#;t be manufactured. Make sure your prototyping process takes this into consideration.

Finally, even if your prototype design is functional and manufacturable, it doesn&#;t mean anyone will want to use it.&#;Prototypes are the only true way to verify the viability of the design in this sense.&#;If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you&#;re well on your way to a successful product launch.

Rapid prototyping is a transformative approach in the world of product development, offering the ability to quickly turn concepts into tangible proofs of concept. Let us outline practical tips for effectively using this type of prototyping techniques, ensuring your projects move smoothly from the drawing board to reality.

Understand Your Objectives

Before exploring it, clearly define what you hope to achieve with each prototype. Whether it is testing a specific function, the ergonomics, or the aesthetic appeal of a product, understanding your objectives will guide your prototyping efforts and make sure that each iteration brings you closer to your final goals.

Choose the Right Technology

Selecting the appropriate technology is critical. 3D printing is often synonymous with rapid prototyping due to its speed and versatility. However, the choice between different 3D printing methods like stereolithography (SLA), selective laser sintering (SLS), or fused deposition modeling (FDM) depends on your specific needs regarding material characteristics, detail resolution, and cost.

Iterate Efficiently

This type of prototyping is all about iteration. By rapidly cycling through versions of your product, you can identify and fix design flaws early in the development process. Adopt a cycle of designing, prototyping, and testing, and then refine based on feedback to evolve your product quickly.

Integrate Feedback Quickly

Incorporate feedback from each prototype test into your design as soon as possible to reduce development time and improve the end product. It includes feedback from potential customers, team members, or anyone involved in the development process. Effective communication and a flexible approach to design changes are essential for making the most of rapid prototyping.

Leverage Prototyping for Marketing

While typically seen as a tool for designers and engineers, rapid prototypes are also powerful marketing tools. They can be used to convey the potential of a product to investors, stakeholders, and early customers. In the context of PPC advertising, having a prototype in ads can increase engagement by showcasing the product&#;s real-world application.

Test Broadly and Often

Comprehensive testing beyond basic functionalities&#;like user interaction and manufacturability&#;can significantly enhance the final product. The broad testing should include everything from usability to the endurance of the materials used, guaranteeing that the product not only meets the design specifications but also stands up to real-world use.

Document Everything

Keep detailed records of each prototype version, the feedback received, and the changes made. The documentation can be invaluable for understanding the development process, making future projects easier to manage, and ensuring compliance with industry standards.

At SmartSites, we recognize the value of rapid prototyping not only in product design but also as an integral part of developing effective website design and search engine optimization strategies. By prototyping our digital projects, we ensure that our solutions are both innovative and perfectly tailored to meet the needs of our clients. Rapid prototyping is more than just a step in the product development process; it is a comprehensive approach that encourages innovation, efficiency, and teamwork. Whether you are a startup or an established company, this type of prototyping can provide the tools you need to succeed in today&#;s fast-paced market.