CHAPTER 11

PROTOTYPING

PREPARED BY:
MUHAMAD ZAKI BIN YUSUP
IAR DEPARTMENT
Definition of prototyping
- an approximation of the product along one or
more dimensions of interest

- concept sketches, mathematical models, and

fully functional preproduction versions of the
product

A process of
developing an
approximation of
the product
 Product Development Process
Concept System-Level Detail Testing and Production
Planning Development Design Design Refinement Ramp-Up

Prototyping is done throughout the development process.

Mission Development
Statement Plan
Identify Establish Generate Select Test Set Plan
Customer Target Product Product Product Final Downstream
Needs Specifications Concepts Concept(s) Concept(s) Specifications Development

Perform Economic Analysis

Benchmark Competitive Products

Build and Test Models and Prototypes

At the end of this chapter, the student should be
able to:

1. Describe the types of prototypes

2. Describe the purpose of prototypes
3. Describe the planning for prototypes
 Types of Prototypes

First dimension Second dimension

Physical vs. Analytical Focused vs.
Prototypes Comprehensive
Prototypes
Types of Prototypes

First dimension
Physical vs. Analytical Prototypes
Physical Prototypes Analytical Prototypes
• Tangible approximation of product. • Mathematical model of product.
• May exhibit unmodeled behavior. • Can only exhibit behavior arising
• Some behavior may be artifact of from explicitly modeled
the approximation. phenomena. (However, behavior is
• Often best for communication. not always anticipated.
• Examples: • Some behavior may be an artifact
of the analytical method.
- look and feel like the product
• Often allow more experimental
- proof-of-concept freedom than physical models.
- validate the functionality • Example:
- computer simulations
- systems of equations encoded
- computer models of three-
dimensional geometry
 Boeing 777 Testing
Brakes Test
• Minimum rotor thickness
• Maximum takeoff weight
• Maximum runway speed
• Will the brakes ignite?
Wing Test
• Maximum loading
• When will it break?
• Where will it break?
BMW Virtual Crash Test

From: Scientific American, March 1999

Types of Prototypes

Second dimension
Focused vs. Comprehensive Prototypes

Focused Prototypes Comprehensive

• Implement one or a few Prototypes
attributes of the product. • Implement many or all
• Answer specific questions attributes of the product.
about the product • Offer opportunities for
design. rigorous testing.
• Generally several are • Often best for milestones
required. and integration.
 Comprehensive Prototypes
Many comprehensive Some comprehensive
prototypes are built. prototypes build (and sold?).
High
Technical or Market Risk

One prototype may be Few or no comprehensive

used for verification. prototypes are built.
Low

Low High
Cost of Comprehensive Prototype
Types of Prototypes
Physical

ball alpha beta

support prototype prototype
final
prototype product

trackball mechanism
linked to circuit
Focused simulation Comprehensive

simulation
of trackball
circuits not
generally
feasible

equations
modeling ball
supports Analytical
4 Uses of Prototypes
• Learning
– answering questions about performance or feasibility
"Will it work?" , "How well does it meet the customer needs?"
– e.g., proof-of-concept model

• Communication
– demonstration of product for feedback
communication with top management, vendors, partners, extended
team members, customers, and investors
– e.g., 3D physical models of style or function

• Integration
– combination of sub-systems into system model
– e.g., alpha or beta test models

• Milestones
– goal for development team’s schedule
– e.g., first testable hardware
Prototype: - As a guideline for decision making during product development
- decisions of what type of prototype to be build and
how to incorporate into the development plan

Analytical Prototypes Physical Prototypes

Generally More Required to Detect
Flexible than Physical Unanticipated
Prototypes Phenomena

PROTOTYPING
PRINCIPLES
A Prototype May
A Prototype May
Reduce Risk of
Restructure Task
Costly Iterations
Dependencies

A Prototype May
Expedite Other
Development Steps
Analytical Prototypes Generally More Flexible than Physical Prototypes
 Contain varies parameters to represent design
alternatives
 Changing of parameter and solve the equations
easier than changing the actual materials in the
physical prototype
 Allows larger changes than in physical prototype
 Narrow the range of feasible parameters, then the
physical prototype used to fine-tune or confirm
the design
Physical Prototypes Required to Detect Unanticipated Phenomena

 Investigate purely geometric issues

 At least one physical prototype is almost
always built in a product development
effort
A Prototype May Reduce the Risk of Costly Iterations

 illustrates role of risk & iteration in

product development

 reduce risk must be weighted against

time & money to build & evaluate the
prototype

 failure costs are low

& technology is well
known
A Prototype May Expedite Other Development Steps

 Savings in duration of subsequent activity

A Prototype May Restructure Task Dependencies

 It may possible to complete

some of the tasks
concurrently by building a
prototype

Use prototypes to reduce uncertainty.

Make models with a defined purpose.

Consider multiple forms of prototypes.

Choose timing of prototype cycles.

- Many early models are used to validate
concepts.
- Relatively few comprehensive models are
necessary to test integration.

Plan time to learn from prototype cycles.

- Avoid the “hardware swamp”.
PROTOTYPING TECHNOLOGIES
3D Computer Modeling

Advantages

Easily visualize 3D form of design

Able to automatically compute physical

properties(mass &volume)

Efficiency creation & one canonical

description of design; focused descriptions
such cross-sectional views, can be created

Can detect geometric interference among
parts for focus analyses (e.g.: kinematics or stress
Example: Development of Boeing 777,

- Able to avoid build full-scale wooden prototype of the plane,

- Use to detect geometric interferences among structural elements and
components of various systems, such as hydraulic lines.
Free-Form Fabrication

called as stereo lithography

enable realistic 3D prototypes to be created

earlier and less expensively

called rapid prototyping

reduce product development time and/or

improve the resulting product

Enabling rapid construction of working prototypes can be :

- embody product concepts quickly and inexpensively,
- increasing ease with which concepts can be communicated to team
members, senior managers, development partners, or potential customers
 Rapid Prototyping Methods
• Most of these methods are additive, rather than subtractive,
processes.
- Build parts in layers based on CAD model.
- SLA=Stereo lithography Apparatus
- SLS=Selective Laser Sintering
- 3D Printing
- LOM=Laminated Object Manufacturing
- Others every year...
 Virtual Prototyping

• 3D CAD models enable many kinds of analysis:

– Fit and assembly
– Manufacturability
– Form and style
– Kinematics
– Finite element analysis
(stress, thermal)
– Crash testing
– more every year...
 Traditional Prototyping Methods
• CNC machining
• Rubber molding + urethane casting
• Materials: wood, foam, plastics, etc.
• Model making requires special skills.
A four-step method for planning a prototype
Step 1: Define the Purpose of the Prototype
- Recall the four purposes of prototypes: learning, communication, integration, &
milestones
- list any integration needs
Step 2: Establish the Level of Approximation of the Prototype
- final product is approximated define
- consider whether physical or analytical prototype best meet its needs
Step 3: Outline an Experimental Plan
- prototype in product development can be thought of as an experiment
- Good experimental helps to extraction of maximum value from prototyping activity.
- The experimental plan : identification of variables of experiment (if any), test protocol,
indicate what measurements will be perform, plan for
analyzing the result data.
- When many variables be explore, efficient experimental design facilitate this process.
Step 4: Create a Schedule for Procurement, Construction, and Testing
- Prototype is consider as a subproject of overall development project,
- When the parts ready to assemble
- Date when first prototype be test
- Date when expects to complete test and produce final results
 Product development - always requires the build & test of prototypes.

 A prototype: - An approximation of product on one or more dimensions

of interest.
- Reduce the risk of cost iterations.
- Expedite other development steps.
- Restructure task dependencies.

 2 dimension to classified successful prototyping:

1. degree of physical vs. analytical
2. degree of comprehensive vs. focus

 Prototypes use: learning, communication, integration, and milestones.

 Physical prototypes : best for communication,

 Comprehensive prototypes : best for integration and milestones.

 Analytical prototypes : more flexible than physical prototypes.

 Physical prototypes : required to detect unanticipated phenomena

 3D computer modeling & free-form fabrication technologies reduce
relative cost & time to create prototypes.

 A four-step method for planning a prototype is:

I. Define the purpose of the prototype.
II. Establish the approximation level of the prototype.
III. Outline an experimental plan.
IV. Create a schedule for procurement, construction, and testing.

 Milestone prototypes: Defined in the product development project

plan.

 The number of prototypes & timing is key elements of overall

development plan.