DIGITAL PIPELINES FOR PRODUCT DESIGN AT

HARLEY-DAVIDSON

ITRO – BLACK SHEEP

INTRO – BIO FOR MATTHEW GUELLER • More than 18 years in the “industrial design side” of engineering

• 7 years at John Deere

• Over 11 at Harley-Davidson as consultant and as employee

• Class A surfacer, digital model maker, visualization expert

HARLEY-DAVIDSON • 110 years of great motorcycles

• Global brand

• Premium products

• Traditional styling that stays true to brand heritage and legacy

• Customer and lifestyle

MY ROLE AT HARLEY-DAVIDSON • Styling Support

• Reverse engineering from scan

• Class A surfacing

• Conceptual Modeling

• Conceptual Visualization

• Gate keeper for the “Art to Part” process

HORSEPOWER AND TORQUE .

There is a fundamental relationship between horsepower and torque.

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

TRADITIONAL INDUSTRIAL DESIGN PROCESS

• Pros • Well-established process • Shallow learning curve • ID centered

• Cons • Many iterations • Very time consuming • Changes and iterations become more challenging later in the process

DIGITAL DESIGN PROCESS

RAPID PROTOTYPING

• 3D printer explosion

• Existing technology

• Concept modeling to RP is easier than CAD

• Truly rapid - 24 hour turn around on parts

• Durable and useable parts

• Disposable

• Scalable

CONCEPT MODELING

• Non-traditional approach

• Tools from movie and gaming industries

• Speed, flexibility and real-time workflow

• Subdivisional modeling

• Autodesk Max, Maya, Mudbox, Alias

• Rhino with T-Splines

• Z-Brush with sculpting

CONCEPT MODELING AUTODESK ALIAS • Modeling: Nurbs Class A surfacing

• Rendering: Mental Ray

• Used in product development and automotive

• User Base: Huge

CONCEPT MODELING AUTODESK MAX • Modeling: Polygons & Sub-D

• Rendering: Mental Ray, iray, V-Ray, plugins

• Used in game development, movies and design

• User Base: Huge

CONCEPT MODELING AUTODESK MAYA • Modeling: Nurbs, Polygons & Sub-D

• Rendering: Mental Ray, V-Ray, plugins

• Used in game development, movies and design

• User Base: Huge

CONCEPT MODELING RHINOCEROUS 3D • Modeling: Nurbs & Sub-D

• Rendering: Some ability, plugins available

• Used in product development and jewelry

• User Base: large and growing

CONCEPT MODELING T-SPLINES • Runs as a plugin for Rhino

• Modeling: Nurbs & Sub-D

• Used in product development and jewelry

• User Base: small but growing

CONCEPT MODELING MUDBOX

• Modeling: Polygon sculpting

• 3D painting

• Used for polygon model refinement, 3d painting and character development

CONCEPT MODELING PIXOLOGIC ZBRUSH • Modeling: Polygon sculpting

• 3D painting

• Rendering: some capability

• Used for polygon model refinement

• 3d painting and character development

CONCEPT MODELING SUB-D MODELING

VISUALIZATION

• Division Mockup Pre-64bit

• Productview from PTC

• Autodesk Showcase

• Autodesk Max with V-Ray and RT

• HDR Light Studio

• Keyshot

• Bunkspeed

VISUALIZATION

Real World benefits

• Speed –Performance scales with hardware

• Design in real-time/visualize in real-time

• Significantly reduces design changes after mockup -no surprises

• Enables designers and Styling to explore more concepts

• Mockups become physical validations of the virtual design

VISUALIZATION KEYSHOT • Fast CPU based

• Easy to use and learn

• Great integration

• HDR Light Studio

VISUALIZATION CHAOS GROUP V-RAY • Highest quality

• Cuda Accelerated

• Great materials

• V-Ray RT

• Max, Maya, Rhino…

VISUALIZATION BUNKSPEED • Fastest CPU/GPU based solution

• Very Scalable

• Truly Real-time performance

• Nvidia iray technology

VISUALIZATION

VISUALIZATION

VISUALIZATION -HARDWARE • Horsepower & Torque • CPU & GPU • Workstation

• Lenovo D30 • Dual 8-core Intel E5-2690 2.9Ghz • 32Gb Ram • 2 Raid -0 Intel SSD • Nvidia Quadro 6000 • Cubix GPU-Xpander with • 4 Nvidia Tesla C2075

• Goals -Real-time motorcycles HD 1080p

VISUALIZATION -HARDWARE • Benchmarks.

CONCLUSION • Looking to the future

• Better integration

• Higher performance

• Mobile performance

• Ptex

• Pixar OpenSubDiv

• Special thanks to Nvidia.

• Cubix Xpander

Digital Pipelines for �Product Design at �Harley-DavidsonItro – Black SheepIntro – Bio for Matthew GuellerHarley-DavidsonMy role at Harley-DavidsonHorsepower and TorqueTraditional Industrial Design ProcessTraditional Industrial Design ProcessTraditional Industrial Design ProcessTraditional Industrial Design ProcessTraditional Industrial Design ProcessTraditional Industrial Design ProcessTraditional Industrial Design ProcessDigital Design ProcessRapid PrototypingConcept ModelingConcept Modeling Autodesk aLIASConcept Modeling Autodesk MaxConcept Modeling Autodesk mAYAConcept Modeling Rhinocerous 3dConcept Modeling T-SpLinesConcept Modeling MudboxConcept Modeling Pixologic ZbrushConcept Modeling Sub-d modelingVisualizationVisualizationVisualization KeyshotVisualization Chaos Group V-RayVisualization BunkspeedVisualizationVisualizationVisualization -HardwareVisualization -HardwareVisualization -sLIDESHOWConclusion