Product development starts with product design. The conceptual design is then translated into a physical prototype. Developing a physical prototype is an essential step in developing a new product or technology. It is usually carried out to evaluate and test the project by system analysts.
A physical prototype can be anything from a simple handmade model to a fully functional model that shows how the conceptual design meets real-world conditions. Nowadays, physical prototypes can be easily manufactured by adopting various rapid prototyping techniques, which is time-saving and cost-effective. This allows many effective physical prototypes to be produced in less time, which attracts many customers due to the better aesthetics and finish of a physical prototype.
Types of physical prototypes
1. Functional prototype
A functional prototype is a physical prototype that has been developed to represent all the characteristics of the conceptual design. A working prototype is also functional and compatible with real-world conditions.
2. Visual prototype
A visual prototype is a physical prototype developed exclusively to represent the appearance, dimensions, and shape of the conceptual design. A visual prototype is not intended to represent the functionality of the conceptual design.
3. Functional prototype
A working prototype is similar to a working prototype, except that the working prototype can be developed on a different scale and using different techniques than the original product.
4. User Experience Prototype
It is a type of physical prototype designed to provide enough information about the product being developed to be made available to researchers for future research purposes.
Rapid Prototyping: Development of physical prototypes
Manufacturers often develop prototypes using rapid prototyping techniques. These rapid prototyping techniques are cost-effective and time-saving. Furthermore, prototypes made using these techniques are effective and aesthetically pleasing. These rapid prototyping techniques are shaping the industry and represent a revolution. Products are often manufactured using 3D printers or other additive manufacturing technologies using CAD model data.
3D printing is a common rapid prototyping technique today that solidifies material using a computer using data from a CAD model to create the physical prototype. 3D printing is becoming increasingly popular among residential and industrial customers because the material used in 3D printing is readily available and cheaper compared to other manufacturing techniques.
Modern modeling software also supports rapid prototyping. This software saves the CAD model in AMF format instead of STL format which results in fewer errors compared to STL format. The interface of this software is also user-friendly so that users can easily create designs with it.
CNC machines are also used by manufacturers to convert the conceptual model into a physical prototype. It is a numerically controlled machine that uses G codes and M codes for cutting, drilling, boring and other manufacturing operations. The CAD model is converted into manufacturing instructions using CAM software. Converting instructions into G codes and M codes allows the machine to produce a high-precision physical prototype. Modern CNC machines in use today are 5-axis, which allows the tool to move along 5 different axes simultaneously, allowing the machine to produce highly efficient and accurate parts.
The difference between 3D printers and CNC printers is the material used in manufacturing. CNC printers are generally used for metallic prototypes, while 3D printers generally use ABS, PLA, and soft PLA to develop physical prototypes. Additionally, a typical 3D printer requires much less space compared to CNC printers, lathes, or precision grinders, making it a much more suitable option for manufacturers. However, in general, the choice of rapid prototyping technique often depends on the choice of material for the physical prototype. Other rapid prototyping techniques used today are
* Shape Deposition Manufacturing (SDM) (and Mold-SDM)
* Solid Soil Hardening (SGC)
*Selective laser sintering (SLS)
* Selective laser melting (SLM)
* Stereolithography (SLA)
* Ballistic Particle Production (BPM)
*Directed Light Manufacturing (DLF)
*Direct Shell Production Casting (DSPC)
*Fused Deposition Modeling (FDM)
*Manufacture of laminated objects (LOM)
*Printing on laminated resin (LRP)
Importance of the physical prototype
Physical prototype development is necessary before developing a product. A prototype helps determine many factors of the future product to be developed, as described below
1. Determination of costs and production problems
By developing physical prototypes before actual production begins, manufacturers can identify any difficulties that may arise during manufacturing operations. This allows all manufacturing processes to be edited or removed. This minimizes production costs. And the manufacturer can choose the optimal product development method that will cost him less and produce accurate, defect-free products.
2. Product evaluation and testing
A conceptual design may differ from the actual product, which can cause a lot of problems for the manufacturer. This can be resolved by first creating a physical prototype using a rapid prototyping technique so that the conceptual design can be tested in real-world conditions. This allows the manufacturer to review all parts and make appropriate changes to the design. Furthermore, each part can be evaluated and tested under real conditions, allowing the manufacturer to easily identify any difficulties that may arise after manufacturing the product.
3. Sell the product
A physical prototype will attract more customers compared to a mere blueprint. The product can be better explained to the customer with the prototype than with the draft. The customer learns about the hidden functions of the product through a working prototype. Furthermore, the aesthetics of the physical prototype can easily attract more customers using rapid prototyping techniques. Therefore, product sales figures can be predicted before production.
4. Patent
A new design or product can easily be patented. With a physical prototype in hand, it is easy to see which design features can be patented and which parts need to be edited to be patentable. This protects manufacturers from lawsuits that may be brought against them in the event of similarity to an already patented product. Furthermore, it is much easier to describe the main features to a patent attorney with a physical prototype than with a conceptual design, allowing the patent to be filed.
Difference between a prototype and a real product
Although engineers and developers do their best to minimize the differences between the prototype and the real product, in general, a prototype may differ from the real product in terms of material used, machining process, appearance, etc.
The material used in the final product is expensive and difficult to manufacture. Therefore, a prototype is usually made from a material that is easy to manufacture but whose properties are identical to those of the final product. In some cases, the material used in the final product is not available, so the prototype is made from the same material. The difference in material can change the appearance and finish of the final product in relation to the prototype.
Final products often need to be manufactured in large quantities, so the manufacturing process can vary. The final product is usually manufactured using a mass production method that is cost-effective and time-saving. This manufacturing process often cannot be used for prototype because the material is often not the same. Furthermore, the manufacturing processes of the final product can be complex, so the prototype is often made using a simple technique. This can also lead to differences in the appearance of the final product and the prototype.
Quality inspection techniques for prototypes and final products can also be different. The final product to be placed on the market is subjected to several quality checks. The physical prototype, on the other hand, is not tested in the same way as the final product due to differences in materials and manufacturing techniques.
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It is obvious that developing a physical prototype is a necessary process in industry today to evaluate and test the design before the manufacturing phase begins. Furthermore, the physical prototype predicts manufacturing costs and any difficulties that may arise during the process, allowing the manufacturer to choose the most cost-effective method.
A physical prototype also attracts more customers compared to a conceptual design. And with the development of software and rapid prototyping techniques, it is not difficult to produce a prototype in much less time and with greater precision. It may vary a little from the actual product, but it is effective for product sales in modern industries.
