SPONSORED FEATURE DESIGN FOR MANUFACTURE
DO YOU INVEST ENOUGH IN PROTOTYPING?
If a one-dimensional picture is worth a thousand words, how much greater
value does a physical prototype offer? Today, a mock-up may be completely virtual – a 3D CAD model - so why build a material version? Chris Arnold of manufacturing contractor ICEE Managed Services makes the case for reality
P
rototyping is generally regarded as essential, but has received far less theoretical and
practical study compared to design, engineering, manufacturing and distribution. Yet this pivotal step can make or break a project, so it should get far more attention. First, what is its purpose and value?
Whether screen-based or material, it is about de-risking the end-product – ensuring the fulfilment of the design specification, performance requirements and customer expectations. It entails stress testing to reveal weaknesses and making any necessary, iterative adjustments to eliminate potential downstream problems. For example, issues in production, installation and maintenance. The prototype also serves to provide important data and information for tooling and fixtures, plus related production and supply chain factors, type testing and QA standards. To get the best out of the investment, what
vital data and information do you want to gain from prototyping? How many interests in the prototype – and subsequent production version - must be served? For example, those of product designers, production engineers, marketing and sales people, senior management, and most of all, the end-user, or customer. Today, collaborative project systems help ensure all the right people contribute value, whether the team venture is confined to one country, or spread worldwide. Prototyping has become virtual. In some sectors
building physical prototypes has almost become redundant. No longer wholly reliant on physical models, thanks to CAD and related manufacturing software a lot of proving, simulation and testing is done on-screen. Increasingly, virtual and augmented reality (VR and
Designed by UK company Graftin Studios, ICEE prototyped and now manufactures these two tables made from mild steel plate, plus a range of related products. Close collaboration between the company’s designer and ICEE ensures bend details and construction methods exactly match aesthetic requirements. (Picture courtesy of Graftin Studios)
18 NOVEMBER 2019 | DESIGN SOLUTIONS
AR) offer enhanced capabilities, plus the advent of Industry 4.0 is poised to bring new benefits.
WILL VIRTUAL MODELLING REPLACE PHYSICAL REALITY? This is doubtful because in some cases, there is no question a physical prototype is essential after preliminary CAD work. People want to touch and feel, fly or drive, or physically experience how something works. They want to ‘kick the tyres’. However, despite the sophistication of 3D
CAD, one of the limitations of screen-based prototyping is just that – the screen is a flat, one-dimensional picture. As in VR or gaming, technology is seductive. It risks leading to complete detachment from reality. In contrast, with a physical prototype,
especially full-size, there is a deeper and actual engagement. For example, take maintenance. With the type of cabinet or equipment enclosures ICEE makes, on a CAD model, after you open the access door, how easy is it to simulate reaching into the back of the internal space and quickly and safely unbolting and replacing an assembly? How readily may fibre optic cables be routed? All that is much simpler to check on a physical model, with certainty and no guessing. Screen-based modelling speeds up the
prototyping process, but a physical prototype brings a design out from a concept into the real world. It sharpens understanding, forces a confrontation with reality and inspires new ideas. In many cases a physical model is the only way to fully ensure everything works properly. Effects like vibration, noise and hazard may be better judged. It is a double- check on reality.
EVEN MORE RAPID PROTOTYPING In a lean world, a company or design consultancy might lack an in-house, fully equipped prototyping workshop. It may have a number of fabrication facilities, but is short on more substantial kit, such as the latest fibre laser or waterjet cutting
One of several CNC press brake bending machines at ICEE's factory, a Bystronic Xpert40 is used to prototype sheet metal parts for a number of customer projects, from commercial and domestic furniture, to telecommunication equipment enclosures and docks for folding bicycle hire. (Picture courtesy of Bystronic Laser AG)
machines, advanced press brake bending kit, or even comprehensive 3D CAD solid modelling. To streamline design to manufacture and save
costs, it helps to use mainstream production equipment for prototyping. At ICEE we do this on a range of modern CNC machines. Where iterations are necessary, the combination of these fast and flexible resources, plus 3D CAD solid modelling and lean manufacturing, compresses the whole prototyping timescale. Sometimes, lack of resources simply means
no time. This is where outsourcing to a specialist manufacturing services contractor like ICEE helps significantly. The company has all the necessary prototyping facilities – plus the means to offer subsequent batch or volume production. The familiarity gained from always working with sophisticated equipment and the constant challenge of tackling new jobs, means ICEE engineers can soon tell you what’s possible, also offering new ideas and insights. And again, if a picture is worth a thousand
words, think what better value you could gain from an actual, physical three-dimensional working prototype.
ICEE Managed Services
sales@icee.co.uk
T: 02392 230 604
www.icee.co.uk
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