reducing the uncertainty in the prototyping process
DESCRIPTION
Reducing The Uncertainty In The Prototyping Process. A Review of Rapid Prototyping Selection Systems. Kevin Steele Rapid Design and Manufacture Centre. Concept Evaluation Techniques. Empathy. Inversion. DFMA Guidelines. Competition Analysis Techniques. CAD. SPC. TIME. Introduction. - PowerPoint PPT PresentationTRANSCRIPT
Reducing The Reducing The Uncertainty In The Uncertainty In The Prototyping ProcessPrototyping Process
Kevin SteeleKevin SteeleRapid Design and Manufacture Rapid Design and Manufacture
CentreCentre
A Review of Rapid Prototyping Selection SystemsA Review of Rapid Prototyping Selection Systems
IntroductionIntroduction
Specification
Conceptual Design
Concept Evaluation
Manufacture
Market Need
Detail Design
TIME
InversionInversion EmpathyEmpathy
Concept Evaluation TechniquesConcept Evaluation Techniques
Competition Analysis Competition Analysis TechniquesTechniques
DFMA DFMA GuidelinesGuidelines
PROTOTYPING TECHNIQUESPROTOTYPING TECHNIQUES
CADCAD
SPCSPC
Overall AimOverall Aim
Specification
Conceptual Design
Concept Evaluation
Manufacture
Market Need
Detail Design
TIME
• Save TimeSave Time
• Reduce Reduce CostsCostsConcept Models
“Fit and Form” Models
Rapid Tooling
Business Business AspectsAspects
TIME
Company Company RestrictiRestrictionsons
Internal Internal PrejudicPrejudiceses
CommerCommercial cial ContextsContexts
Prototyping OptionsPrototyping Options
PROTOTYPING TECHNIQUESPROTOTYPING TECHNIQUES
PHYSICALPHYSICAL
L.ML.MCNCCNCMANUALMANUAL
VIRTUALVIRTUAL
MANUAL MANUAL RENDERINGRENDERING
3D 3D CADCAD
VRVR
NONENONE
• L.M = Layered Manufacture L.M = Layered Manufacture (RP/T)(RP/T)
Issues within Layered Issues within Layered ManufactureManufacture• Rapidly Growing number of Rapidly Growing number of
TechnologiesTechnologies• Growing Number of InteractionsGrowing Number of Interactions
– 25 + RP Technologies : 19 + RT 25 + RP Technologies : 19 + RT TechnologiesTechnologies
– Escalating Number of MaterialsEscalating Number of Materials
• Growing User BaseGrowing User Base– Exponential rise in the number of RP Exponential rise in the number of RP
systems in existencesystems in existence
The Process Chain The Process Chain ConceptConcept
REQUIREMENTS DEFINITION (RP&T)
CONCEPT MODELLING
3DP ThermoJetObjet Genesys
Prodigy JP5
RAPID PROTOTYPING
SLA SLS LOM FDM SANDERS
CNC DMLS Mod
ell
ing
M
od
ell
ing
T
ech
nolo
gT
ech
nolo
gie
sie
s
Vacuum Casting KeltoolInv. Casting
Sand Casting
Metal Filled Epoxy Tooling
Spray Metal ToolingP
ost
P
ost
P
rocess
es
Pro
cess
es
Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder
Mate
rials
Mate
rials
Wax Infiltration
Case Study 1: McAlpine Case Study 1: McAlpine PlumbingPlumbing• Requirements: Requirements:
Must exhibit Must exhibit waterproof waterproof propertiesproperties
• Process Chain Process Chain Used: FDM with a Used: FDM with a wax infiltrantwax infiltrant
Process Chain Used: Process Chain Used: McAlpinesMcAlpines
REQUIREMENTS DEFINITION (RP&T)
CONCEPT MODELLING
3DP ThermoJetObjet Genesys
Prodigy JP5
RAPID PROTOTYPING
SLA SLS LOM FDM SANDERS
CNC DMLS Mod
ell
ing
M
od
ell
ing
T
ech
nolo
gT
ech
nolo
gie
sie
s
Vacuum Casting KeltoolInv. Casting
Sand Casting
Metal Filled Epoxy Tooling
Spray Metal ToolingP
ost
P
ost
P
rocess
es
Pro
cess
es
Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder
Mate
rials
Mate
rials
Wax Infiltration
Case Study 2: TronicCase Study 2: Tronic
• Rubber seal for Rubber seal for protecting sub-protecting sub-sea connectorsea connector
• Process Chain: Process Chain: ZP11 Powder ZP11 Powder combined with combined with elastomer elastomer infiltrantinfiltrant
Process Chain Used: Process Chain Used: TronicTronic
REQUIREMENTS DEFINITION (RP&T)
CONCEPT MODELLING
3DP ThermoJetObjet Genesys
Prodigy JP5
RAPID PROTOTYPING
SLA SLS LOM FDM SANDERS
CNC DMLS Mod
ell
ing
M
od
ell
ing
T
ech
nolo
gT
ech
nolo
gie
sie
s
Vacuum Casting KeltoolInv. Casting
Sand Casting
Metal Filled Epoxy Tooling
Spray Metal ToolingP
ost
P
ost
P
rocess
es
Pro
cess
es
Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder
Mate
rials
Mate
rials
Wax Infiltration Elastomer
Infiltration
Case Study 3: GaltronicsCase Study 3: Galtronics
• Mobile Phone Mobile Phone antenna frameantenna frame
• ZP100 & ZP100 & Cyanoacrylate Cyanoacrylate Resin: Resin: UnsuitableUnsuitable
• Correct Process Correct Process Chain: FDMChain: FDM
Process Chain Used: Process Chain Used: GaltronicsGaltronics
REQUIREMENTS DEFINITION (RP&T)
CONCEPT MODELLING
3DP ThermoJetObjet Genesys
Prodigy JP5
RAPID PROTOTYPING
SLA SLS LOM FDM SANDERS
CNC DMLS Mod
ell
ing
M
od
ell
ing
T
ech
nolo
gT
ech
nolo
gie
sie
s
Vacuum Casting KeltoolInv. Casting
Sand Casting
Metal Filled Epoxy Tooling
Spray Metal ToolingP
ost
P
ost
P
rocess
es
Pro
cess
es
Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder
Mate
rials
Mate
rials
Wax Infiltration Elastomer
Infiltration
Case Study 4: AgilentCase Study 4: Agilent
• Only Company Only Company with in-house RPwith in-house RP
• User of 3DP, User of 3DP, SLA, and SLSSLA, and SLS
• Company Company Procedures get Procedures get in the way of in the way of RP AdoptionRP Adoption
Case Studies - Case Studies - ConclusionsConclusions• Important to establish prototype Important to establish prototype
requirements before embarking on RP requirements before embarking on RP • Knowledge of Process Capability Knowledge of Process Capability
imperativeimperative
• Vital to have Vital to have understandingunderstanding of process of process relationships between RP, RT and relationships between RP, RT and MaterialsMaterials
• Business Considerations can serve as an Business Considerations can serve as an obstacle to successful RP implementationobstacle to successful RP implementation
Previous Approaches 1Previous Approaches 1
• Simple RP Simple RP Selection Expert Selection Expert SystemsSystems
• Lack depth of Lack depth of information, no information, no Process Chain Process Chain capabilitycapability
Previous Approaches 2Previous Approaches 2
• Process Chain Process Chain SelectorsSelectors
• RAPTEC, RAPTEC, PROTOOLPROTOOL
• Select Select complete complete process process chainschains
Previous Approaches 3Previous Approaches 3
• Process Chain Process Chain Configuration Configuration SystemsSystems
• CAPP, I-ViP CAPP, I-ViP RP-SelectorRP-Selector
• Design Design process process Chains from Chains from scratchscratch
Selection System Selection System DrawbacksDrawbacks• Difficulty in turning identifying Difficulty in turning identifying
model requirements and turning model requirements and turning them into a specificationthem into a specification
• Reliance on making subjective Reliance on making subjective judgements on model geometry & judgements on model geometry & requirementsrequirements
• Existing Systems do not take into Existing Systems do not take into account external influences on account external influences on design processdesign process
Proposed ModelProposed Model
Research IssuesResearch Issues• Methodology for Correct RP/T Process Methodology for Correct RP/T Process
Chain SelectionChain Selection– Structuring of Prototype RequirementsStructuring of Prototype Requirements– Understanding of the effect of external Understanding of the effect of external
influencesinfluences
• Process Capability/Materials DatabaseProcess Capability/Materials Database– Detailed Study into RP CapabilitiesDetailed Study into RP Capabilities– New Means of Structuring the InformationNew Means of Structuring the Information
• Embodiment of MethodologyEmbodiment of Methodology
Research StrategyResearch Strategy
• Company ResearchCompany ResearchEstablish Attitudes/Practices within Establish Attitudes/Practices within
PrototypingPrototypingExamine current uses of PrototypesExamine current uses of Prototypes
• Evaluate Techniques such as QFD Evaluate Techniques such as QFD and Benefit Value Analysis for RP and Benefit Value Analysis for RP Specifiaction generationSpecifiaction generation
• Design and Evaluation of SystemDesign and Evaluation of System
Thank You for Your Thank You for Your AttentionAttention