MATERIALS • PROCESSES
The idea that a single prototype will be able to
represent the design intent and be all things to all departments without spending the time and money on the design process is how optimism missteps expectations. Participate in enough of these project plans and
you understand why the various players are motivated to make the prototype stage so important: fear. So let’s step back. What is trying to be achieved? What are the worries?
GET DOWN TO THE SPECIFICS Making a prototype to answer a specific line of questioning is far more appropriate and is more realistic to what a prototype is. If I want to get an idea of what a product will look like, then CGI is probably the most adaptable method, rather than a physical prototype. Designers who sketch in 3D from the outset are the most useful to work with when it comes to strong realistic visuals: unambiguous communication of ideas that have the ability to inspire even the most faint-hearted. If spatial context is required, then a simple block model can support the visuals, made with just a minor tweak of the 3D data. Take this to the latest level and with virtual reality you can even interact with your ideas. However, sometimes the question is not ‘what will
it look like?’ but ‘will it work?’ This is answered by the prototypes that exist in the domain of R&D. Here sticky-backed plastic and plasticine are not necessarily out of place. Often referred to as ‘jury rigs’, all manners
of methods are employed to reach an understanding of something that was theorised. When R&D has provided a specification and the
design intent satisfies the marketing objectives, then the process moves to its next level. Engineering development provides the details for assembly and the geometry of parts with a clear understanding of the manufacturing processes. During this process, 3D printing comes into its own. Designers that have access to this technology get instant feedback of fit and assembly difficulties and those able to create high-resolution plastic parts throughout the process means the number of problems that reach pre- production falls considerably.
PHYSICAL VERSUS VIRTUAL During the engineering development process we may find questions that are about strength, reliability and performance. The use of a physical prototype here must be considered very carefully, especially when using rapid prototypes. The limitations of the materials and processes may do more to worry the observer than reassure. This is where virtual prototyping comes is most useful. Computers can mathematically simulate the real world and offer the sort of reassurance that comes from science rather than simple faith. However, the area of rapid prototyping is developing swiftly. New technologies and materials might soon mean that it can provide greater accuracy, flexibility and reassurance to design teams, clients and investors.
WHERE FUNCTION MEETS FORM T
he tagline that 3form Design operates under is simple: “We make great ideas into great products”. However, the processes the UK-headquartered company deploys to satisfy that claim are anything but simple. Companies come to 3form Design when they want to turn their idea into a game-changing product in their category. The firm’s team of product designers do this by combining an instinct for aesthetics and branding with the real application of engineering, science and manufacturing knowledge. Its dynamic turnkey ‘design and build’ service allows the company to partner with clients across multiple industries from first concept and development through to box-
delivered production of commercially savvy products. The company’s knowledge of design, engineering and manufacturing means it is not constrained by preconceptions and it never designs to a set of rules. Instead, it says that its experts believe that anything is possible: any product, any process, any material.
3D printing being
performed using a Fortus printer from Stratasys
3form Design champions a design process that embraces and enhances the digital tools available today. Working in the 3D environment from the beginning, it focuses on maintaining synergy between the aesthetic, computational and manufacturing know-how for a faster, safer passage. l
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