Virtual Prototyping & Rapid Prototyping

Jonathan Prince & Greg Morehouse

What are we talking about?

• What is Virtual Prototyping from an engineering

perspective?

• Simulation of Rapid Prototypes

• Why perform Virtual Prototyping and Rapid

Prototyping?

• Time to market

• Accuracy of design

• Risk mitigation

• Virtual Prototyping Process - Bogie Case Study!

VIRTUAL PROTOTYPING

Types of Virtual Prototyping

• Stress (Structural) Analysis (FEA)

• Understand the effects of possible loads and restraints early

• Remove unnecessary weight & material

• Flow Analysis (CFD)

• Fluid flow, losses, flow lines, heat transfer, turbulence

• Coupled Fluid / Structural Interaction (FSI)

• Mold Flow Analysis

• Will the mould fill?

• Will the part last?

• Computer Aided Machining (CAM)

• Can the mold / part be made?!

• Risk Mitigation

• Get it right for final (productionised) prototyping!

• Understanding the layered build process

• Understanding the difference in material

properties - strength, ductility & stiffness

• Isotropic, Orthotropic vs. Anisotropic?

• Non-Linear materials properties

• Simulating fatigue

• Simulating creep

• Pitfalls for the uninitiated!

RAPID PROTOTYPING STRUCTURAL SIMULATION

Especially for Additive Manufacture!

VIRTUAL PROTOTYPING?

Nah, I’ll just whip one up!

http://www.3ders.org/articles/20121204-tested-3d-printed-gun-breaks-within-6-shot.html

RAPID PROTOTYPING SIMULATION

Especially for Additive Manufacture!

VIRTUAL PROTOTYPING & RAPID PROTOTYPING

Why are they important?

• Time to market

• Crucial to product profitability

• Accuracy of design

• Crucial to the brand, the product and success of the

company

• Mitigating risk

• What will it cost if you get it wrong?

RAPID PROTOTYPING

Tensile Strength Optimisation

From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/

Part and material properties in selective

laser melting of metals

Jean-Pierre.Kruth@mech.kuleuven.be

RAPID PROTOTYPING

Techniques

From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/

RAPID PROTOTYPING

Unexpected Results!

From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/

RAPID PROTOTYPING

Additive Manufacturing Risks

From: Thinking ahead the Future of Additive Manufacturing – Analysis of Promising Industries

Risk: The probability of something

happening multiplied by the resulting

cost ($$ or life) if it does.

Risky? Really?!

Why is virtual and rapid prototyping important?

Accuracy of Design

Fit for Purpose?

• Do things Fit?

• Design Intent: Do they work as intended?

• Can it take the loads?

• What are the loads, how is it used and restrained?

• Can it handle the environmental conditions?

• What are the long term, ongoing scenarios?

• How might this be used & abused?

• Rubbish in = rubbish2 out

Analysis process

• Progressive

Analysis process

• Progressive

• Conservativerailpictures.net image © phil cotterill

Analysis process

• Progressive

• Conservative

• Controlled

Analysis process

• Progressive

• Conservative

• Controlled

• Validated

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 and rapid 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 or inject plastic!