Reducing The Uncertainty In
The Prototyping Process
A Review of Rapid Prototyping Selection Systems
Kevin Steele
Rapid Design and Manufacture Centre
Introduction
Concept Evaluation Techniques
Inversion
Empathy
DFMA
Guidelines
Market Need
Specification
Conceptual Design
Competition Analysis
Techniques
Concept Evaluation
CAD
Detail
Design
Manufacture
PROTOTYPING TECHNIQUES
SPC
TIME
Overall Aim
• Save Time
Market Need
Specification
• Reduce Costs
Conceptual Design
Concept Models
Concept Evaluation
Detail Design
“Fit and Form”
Models
Rapid Tooling
Manufacture
TIME
Business Aspects
Commercial
Contexts
Internal
Prejudices
Company
Restrictions
TIME
Prototyping Options
PROTOTYPING TECHNIQUES
NONE
VIRTUAL
MANUAL
RENDERING
3D
CAD
VR
PHYSICAL
MANUAL
CNC
• L.M = Layered Manufacture (RP/T)
L.M
Issues within Layered Manufacture
• Rapidly Growing number of Technologies
• Growing Number of Interactions
– 25 + RP Technologies : 19 + RT Technologies
– Escalating Number of Materials
• Growing User Base
– Exponential rise in the number of RP systems in
existence
The Process Chain Concept
Post
Processes
Materials
Modelling
Technologies
REQUIREMENTS DEFINITION (RP&T)
CONCEPT
MODELLING
RAPID
PROTOTYPING
3DP ThermoJet
Objet Genesys
Prodigy JP5
SLA SLS LOM
FDM SANDERS
CNC DMLS
ZP11/14
Powder
Inv. Casting
Wax
ABS
SLA Resins
Vacuum Casting
Sand Casting
RapidSteel
Keltool
Spray Metal
Tooling
LOM Papers
Metal Filled Epoxy
Tooling
Wax
Infiltration
CastForm
Case Study 1: McAlpine Plumbing
• Requirements: Must
exhibit waterproof
properties
• Process Chain Used:
FDM with a wax
infiltrant
Process Chain Used: McAlpines
Post
Processes
Materials
Modelling
Technologies
REQUIREMENTS DEFINITION (RP&T)
CONCEPT
MODELLING
RAPID
PROTOTYPING
3DP ThermoJet
Objet Genesys
Prodigy JP5
SLA SLS LOM
FDM SANDERS
CNC DMLS
ZP11/14
Powder
Inv. Casting
Wax
Infiltration
Wax
ABS
SLA Resins
Vacuum Casting
Sand Casting
LOM Papers
RapidSteel
Keltool
Metal Filled Epoxy
Tooling
Spray Metal
Tooling
CastForm
Case Study 2: Tronic
• Rubber seal for
protecting sub-sea
connector
• Process Chain: ZP11
Powder combined with
elastomer infiltrant
Process Chain Used: Tronic
Post
Processes
Materials
Modelling
Technologies
REQUIREMENTS DEFINITION (RP&T)
CONCEPT
MODELLING
RAPID
PROTOTYPING
3DP ThermoJet
Objet Genesys
Prodigy JP5
SLA SLS LOM
FDM SANDERS
CNC DMLS
ZP11/14
Powder
Inv. Casting
Wax
Infiltration
Wax
ABS
SLA Resins
Vacuum Casting
Sand Casting
RapidSteel
Keltool
Spray Metal
Tooling
LOM Papers
Metal Filled Epoxy
Tooling
Elastomer
Infiltration
CastForm
Case Study 3: Galtronics
• Mobile Phone
antenna frame
• ZP100 &
Cyanoacrylate Resin:
Unsuitable
• Correct Process
Chain: FDM
Process Chain Used: Galtronics
Post
Processes
Materials
Modelling
Technologies
REQUIREMENTS DEFINITION (RP&T)
CONCEPT
MODELLING
RAPID
PROTOTYPING
3DP ThermoJet
Objet Genesys
Prodigy JP5
SLA SLS LOM
FDM SANDERS
CNC DMLS
ZP11/14
Powder
Inv. Casting
Wax
Infiltration
Wax
ABS
SLA Resins
Vacuum Casting
Sand Casting
RapidSteel
Keltool
Spray Metal
Tooling
LOM Papers
Metal Filled Epoxy
Tooling
Elastomer
Infiltration
CastForm
Case Study 4: Agilent
• Only Company with
in-house RP
• User of 3DP, SLA,
and SLS
• Company
Procedures get in
the way of RP
Adoption
Case Studies - Conclusions
• Important to establish prototype
requirements before embarking on RP
• Knowledge of Process Capability imperative
• Vital to have understanding of process
relationships between RP, RT and Materials
• Business Considerations can serve as an
obstacle to successful RP implementation
Previous Approaches 1
• Simple RP Selection
Expert Systems
• Lack depth of
information, no
Process Chain
capability
Previous Approaches 2
• Process Chain
Selectors
• RAPTEC,
PROTOOL
• Select complete
process chains
Previous Approaches 3
• Process Chain
Configuration
Systems
• CAPP, I-ViP
RP-Selector
• Design process
Chains from
scratch
Selection System Drawbacks
• Difficulty in turning identifying model
requirements and turning them into a
specification
• Reliance on making subjective judgements
on model geometry & requirements
• Existing Systems do not take into account
external influences on design process
Proposed Model
Research Issues
• Methodology for Correct RP/T Process Chain
Selection
– Structuring of Prototype Requirements
– Understanding of the effect of external influences
• Process Capability/Materials Database
– Detailed Study into RP Capabilities
– New Means of Structuring the Information
• Embodiment of Methodology
Research Strategy
• Company Research
Establish Attitudes/Practices within Prototyping
Examine current uses of Prototypes
• Evaluate Techniques such as QFD and
Benefit Value Analysis for RP Specifiaction
generation
• Design and Evaluation of System
Thank You for Your Attention