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Understand the important aspects of digital design and digital manufacturing, what technologies are available, and how to embed rapid prototyping technologies to fast track your development program.
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Realities of Virtual PrototypingJonathan Prince
What are we talking about?
• What is virtual prototyping from an engineering perspective?
• Why perform virtual prototyping?• Time to market• Accuracy of design• Risk mitigation
• Real life examples of the difference virtual prototyping can make…
What is virtual prototyping?
• Understanding the build process• Simulating Loads and working conditions• Simulating fatigue- long term loads• Simulating the component manufacture• Understanding the manufacturing/ assembly
process
Virtual prototyping?Nah, I’ll just whip one up!
• Stress Analysis• Understand loads / forces early• Remove unnecessary weight / material
• Flow Analysis• Will the mould fill?• Will the part last?
• CAM – Machining• Can the mould/ part be made?!
• Rapid Prototyping• Visualisation• Check fits
Embrace Technology
Why is virtual prototyping important?
• Time to market• Crucial to product profitability
• Accuracy of design• Crucial to the brand, the product and success of the
company
• Mitigating risk
Why is virtual prototyping important?
Time to market
Late to Market
Lost revenue
1 2 3 4 5
Volumes/ Sales
Time
Time to market
Time to market
• “Products that come to market six months late but on budget will earn 33% less profit over five years…
• In contrast, coming out on time and 50% over budget cuts profits by only 4%”.
• - McKinsey and Company
Why is virtual prototyping important?Mitigating risk
www.latimes.com
Risk: The probability of something happening multiplied by the
resulting cost ($$ or life) if it does.
Risky? Really?!
Case study: Life changing!
Why is virtual prototyping important?Accuracy of design
Fit for Purpose?
• Can it take the loads?• What are the loads?
• Can it handle the environmental conditions?• What are the long term, ongoing scenarios?
• How might this be used & abused?
• Rubbish in = rubbish2 out
Case study: How hard can it be?
• Feller/De-limber• $150k per unit• Failing in the field • Analysed for failure
• And then we checked it in the field!
Case study: Lucky?!
• $1/4M prototype• 25 Year life • 10 Million cycles• 3 month test cycle
Analysis process
• Progressive
Analysis process
• Progressive• Conservative
railpictures.net image © phil cotterill
Analysis process
• Progressive• Conservative• Controlled
Analysis process
• Progressive• Conservative• Controlled• Validated
Case study: Lucky?!
• $1/4M prototype• 25 Year life • 10 Million cycles• 3 month test cycle
• Right first time!
Get it right, before you cut steel!
Design without analysis is like pilots without instruments; they
know they’re flying, but they might not know exactly where
they are!
Over the Top?
Summary
• Build virtual prototyping into your development process
• Don’t skimp on the engineering
• Rubbish in = rubbish2 out
• Develop a virtual prototyping methodology
• Get it right before you cut steel
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