SPONSORED FEATURE
At what point do you switch from on-screen 3D modelling to a physical prototype? A not uncommon risk in designing new and bespoke enclosures or structures in sheet metal is moving too soon to a material model. Chris Arnold of manufacturing services contractor ICEE Managed Services offers his view. Some fundamental questions: whether virtual or actual, what is the point of a prototype? What is its purpose and what do you want to test, prove or discover? It may be obvious, but before investing in the process, ask questions and define exactly what everyone requires. With today’s CAD-based 3D solid modelling, a great many questions may be answered by testing and analysing an on-screen model, a virtual prototype. Calculations and proveout take less time, especially when several options or iterations have to be explored in short order. In comparison, building one or more physical models to find out may be hugely wasteful. In some cases it may be unnecessary. Vehicles in the automotive sector
3D modelling saves time have already been made, derived straight from a CAD model or screen-based prototype. In many industries, because it is so commonly used, sheet metal is often thought of as a relatively simple and low-cost construction material. It is, but depending on the complexity of the application, it also has its own set of challenges and requirements. Imagine a large enclosure featuring panel construction, many lockers, lockable doors, weatherproofing, and an operating system to access contents, all these factors have to be optimised in design and manufacturing terms. For a start, it may be very hard to visualise and configure all the assembly details. Before CAD it was painstakingly done on paper, together with one or more physical prototypes. Today we have 3D solid modelling on a desktop screen to help understand, de-risk and optimise what is necessary, all in a fraction of the time, at least cost and with much higher productivity. Which is why it is so important to do as much prototype development onscreen, before moving to making a physical prototype. On-screen is easier On-screen, it is comparatively easy to test ideas and principles and mitigate risks. For example, check safety conformance, calculate material strengths, or find weight savings. In other
words, address a host of functional, material and compliance issues before going anywhere near committing to build what may be a costly physical prototype. At ICEE, for our customers, we specialise in new product development, prototyping and subsequent production. We offer a complete solution, from on-screen optimisation of design for manufacture, to modelling ‘soft’ and building ‘hard’ prototypes, leading to one-off or batch production. In most cases, we also fully fit-out in the factory, ready for deployment and then install the
Chris Arnold, Key Account Manager, ICEE Managed Services Ltd.
Jumping to a physical prototype too early risks wasting time and money on making changes that could have been done far more efficiently and cost-effectively by 3D modelling on-screen
enclosure to a pre-installed base, thereafter maintaining and updating equipment in the field. Some customers give us a design concept or simply a sketch, leaving design for manufacture, prototyping and production completely to us. This is fine because we can then ensure the outcome wholly conforms to the customer’s design requirements, but costs least to make, is lean and optimised to production
processes. In turn, the customer pays less. Learned sources say 70-80 per cent of product costs are generated at the concept stage, which includes design for manufacture, so it pays to look very carefully at this key area. We also receive designs where the customer specifies construction, fabrication and fastening details. In these cases, when quoting, we always run the designs through our 3D modelling and design for manufacture software. We do this to check we can make and assemble the parts, at least cost for the customer and ourselves. For example, we ask for a CAD STEP file and flatten out the sheet metal designs (there may be a hundred or more parts and panels). This reveals several critical factors, including what the true dimensions of the flat part must be to allow for important ‘K’ factor bending allowances; whether holes or apertures are too close to bends and risk distortion; and how many ‘nested’ parts may be economically cut from a raw panel to minimise costly and wasteful scrap. We advise the customer, enabling timely adjustments to be made. Inspiring new ideas In both cases above, it pays to spend time modelling and checking the design on-screen, before moving to make and build a physical prototype. That is not to say a 3D model will answer
every question and solve all potential problems. In our experience, the real value of a physical prototype includes bringing a design out from a virtual concept into the real world. It sharpens understanding, forces a confrontation with reality and inspires new ideas. In some cases a physical model is the only way to fully ensure everything works properly. Effects like vibration, noise and hazard may be better judged. It is a double check on reality. In short, do as much modelling and development work on-screen and only move to a physical prototype when you are sure as much uncertainty as possible has been eliminated. This includes ensuring efficient and least-cost design for manufacture. Jumping to a physical prototype too early risks wasting time and money on making changes that could have been done far more efficiently and cost-effectively on-screen. ICEE has a lot of experience in both ‘soft’ and ‘hard’ prototyping. We have seen the issues raised above so we are able to offer advice about how to avoid them and achieve high quality outcomes. Right-first-time solutions that save time and money. 8 To find out more please contact: ICEE Managed Services Ltd. 20 Arnside Road, Waterlooville Hampshire PO7 7UP Telephone: 02392 230 604. Email: sales@icee.co.uk Web: www.icee.co.uk