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.
2. 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…
3. 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
4. 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
5. 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
7. Late to Market
Lost revenue
1 2 3 4 5
Volumes/ Sales
Time
Time to market
8. 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
9. Why is virtual prototyping important?
Mitigating risk
www.latimes.com
10. Risky? Really?!
Risk: The probability of something
happening multiplied by the resulting
cost ($$ or life) if it does.
12. Why is virtual prototyping important?
Accuracy of design
13. 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
14. 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!
15. Case study: Lucky?!
• $1/4M prototype
• 25 Year life
• 10 Million cycles
• 3 month test cycle
20. 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!
21. Over the Top?
Design without analysis is like pilots
without instruments; they know they’re
flying, but they might not know exactly
where they are!
22. 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
