Rapid Prototyping- A Part of Mechanical Design

What is Rapid Prototyping?

Rapid prototype or rapid prototyping is relatively a new term and in simple words, it is created to quickly evaluate the visual and functionality of an engineering product's design.

A prototype in an Engineering Design San Francisco CA product design that is used to test the technology, evaluate the design, or analyze the working to provide product specification for a real and working system.

Prototypes are an integral part of engineering product design and more importantly, it is an overall development process of new products. In the new product design process, rapid prototyping can be executed at any stage of the product development cycle. It can be used for any component or subcomponent repeatedly.

The prototype can be used in other contexts like in semantics, software programming and application development, etc, although the purpose of using a prototype in other contexts is the same.

Types of Prototyping in product design

The categories of prototyping depend upon the required degree of accuracy (Fidelity) or at the stage of product development where it is used. 

Fidelity types of prototyping

Prototypes don't need to look like final products, it can vary according to the needs of the product design engineer that is required to achieve the final product. A rapid prototype can be categorized in terms of accuracy. The degree of the prototype may vary from basic low-fidelity to high-fidelity in its appearance, functionality, size, and user interface.

What is a Low-fidelity and high-fidelity prototype?

·      Low-fidelity prototype

A low-fidelity prototype can be quickly produced and a simple prototype. It is used to test the border concept of the final product. An example of this type of prototype is Paper sketches to cardboard mock-ups.

·      High-fidelity prototype

In a High-fidelity prototype, the appearance and functionality of the prototype are closer and similar to the final product.

NPD stage types of Prototyping

Product design, prototyping process of the build, review, and refine classified into four major stages of the design process. These major stages are:

·      product planning,

·      conceptual design,

·      embodiment design

·      detailed design  

The major parts further divided into the following prototypes:

·      Proof of concept prototypes

·      Demonstration or presentation model prototypes

·      Functional prototypes

·      Aesthetic or industrial design prototypes

·      Final factory sample

·      Alpha & beta build prototypes

What is the importance of Prototyping in Mechanical Design?

In the competitive environment of these days, companies continuously develop and introduce new products to their consumers. In the fast-moving modern days, faster development of products and innovation of new technologies is the key to the success of companies. Due to these reasons, the importance of rapid prototyping is also increasing along with fast-moving technologies. Here are some points that can be achieved by rapid prototyping:

·      Prototyping plays a vital role in the faster development of new products.

·      Early-stage concept validation of fit, form, and function of the Engineering Design San Francisco CA.

·      Final stage product verification against the business objectives and technical requirements.

·      Rapid prototyping allows functionality testing to achieve the goals of the final product.

·      Prototyping gives the hands-on user experience to get feedback.

Types of rapid prototyping techniques

Mentioned below are the types of rapid prototyping technology available for the Mechanical Design Engineer San Francisco CA:

·      Additive manufacturing

·      Stereolithography (SLA)

·      Selective laser sintering (SLS)

·      Direct metal laser sintering(DMLS)

·      Fused Deposition Modelling (FDM)

·      Binder jetting

·      Poly jetting

·      Other techniques

·      CNC Machining Prototyping

·      Vacuum casting

·      Investment casting

Advantages and Disadvantages of Rapid Prototyping

Advantages of rapid prototyping

·      Reduced design & development time

·      Reduced overall product development cost

·      Elimination or reduction of risk

·      Allows functionality testing

·      Improved and increased user involvement

·      Ability to evaluate human factors and ergonomics

Disadvantages of rapid prototyping

·      Lack of accuracy

·      Added initial costs

·      Some rapid prototyping processes are expensive and  not economical.

·      Requires skilled labor

·      Material properties cannot be matched

·      The range of materials are limited

·      End-user confusion

·      Overlooking some key features due to lack of prototyping process.

Machine Designing Process

What is the job of an Mechanical Design Engineer?

The mechanical design engineer job demands a diversity of everyday tasks that center around the big picture of a project. Depending on the project, the mechanical engineer will spend a lot of time on one aspect of the creation process, which is a strong way to make the other parts easier. They may juggle various projects at once and change tasks throughout the day. Mechanical engineer responsibilities include:

·      Designing equipment modifications and system changes

·      Evaluating current systems for weakness and opportunities for improvement

·      Creating, building, and testing multiple designs

·      Calculating the cost of the improvement versus the benefits to the company

·      Presenting budget proposals for the creation of additional tools to improve production

·      Listening to employees and floor managers to understand their problems

·      Analyzing the financial costs of production and looking for waste

·      Recommending changes based on beta-testing

·      Training employees and managers on the new equipment and its effectiveness

·      Planning long-term system overhauls and changes

·      Reporting results to colleagues facing similar challenges

·      Isolating design tests from other tests to ensure results accuracy

·      Documenting specifications and design needs for launch

Mechanical Engineers San Francisco CA typically work in an office environment for a large company or an engineering agency. They will be given a desk, computer, and phone. Depending on the company, they may have a drafting table, though today most companies create blueprints and prototypes digitally. They may also receive a laptop or tablet to bring with them when they have meetings in different parts of the company, or for working at home.

While Mechanical Design Engineer San Francisco CA spend most of their time at their desks, they also need to walk around to visit different parts of the production process. This may require several hours on the production floor or in the distribution center learning how everything operates. These environments can be loud and uncomfortable, depending on what the company produces.

Some mechanical engineers work on a contractor or freelance basis. This gives them the opportunity to work from home, though they may have to travel extensively to meet with clients and check on different projects. The mechanical engineer is typically traveling between the office and work site to better understand the problems and needs of employees.

When looking for a mechanical Engineering Design San Francisco CA job, look for regions with a strong manufacturing economy. Cities like Detroit are always looking to improve their processes and create products more efficiently and safely.

What are the steps involved in Machine Design Procedure?

·      Understand the Requirements:
The first step of Mechanical Design Engineer San Francisco CA a high performance machine is recognising the need i.e. understanding the purpose of design. Preparing a complete statement of the problem that includes details about the aim or purpose for which the mechanical design project is proposed.

·      Analyse and Evaluate the Design Mechanism:
Shortlist and analyse various possible mechanisms for the machine. Select the best mechanism for your design that will give this machine the desired motion.

·      Analysis of Forces:
Analyse how every component of a machine will fit in and interact with each other, also analyse what forces act on each and every component of the mechanical equipment and the energy transmitted by each component.

·      Design of Elements:
All the components of equipment are subject to stress and other forces during operation. These stresses affect the strength of the machine. Hence analysing these stresses is important to design mechanical equipment that is durable and can endure the stresses of real world working conditions.

·      Material Analysis and Selection:
Based on the analysis of stresses that work upon the machine components individually select the appropriate material for machine component design.

·      Design Iteration for Manufacturing:
Design changes that do not affect the performance of the product but facilitates easy manufacturing the machine and its components is advisable.

·      Creation of Detailed Mechanical Drawings:
Create the detailed drawings of each component and assembly of the machine. Complete specification using CAD capabilities can be of great assistance for the manufacturing process.