Manufacturing

Jamie Z 2025-08-17

Prototyping

Engineers perform calculations to assess their design for suitability in relation to the success criteria. This process is known as physical prototyping.

Physical Prototyping

• Creating a tangible, real-world model of a product (e.g., 3D print, mock-up, functional prototype).

Advantages

• Real-world testing – allows testing of ergonomics, usability, durability, and physical performance.
• Better communication – stakeholders can see, touch, and interact with the product, improving feedback.
• Detects practical issues – reveals problems with materials, assembly, weight, and physical constraints.
• Customer & investor appeal – a tangible prototype can help in pitching ideas and securing buy-in.

Disadvantages

• Costly – materials, equipment, and manufacturing can be expensive.
• Time-consuming – building physical models often takes longer than virtual iterations.
• Difficult to modify – changes require rebuilding or significant rework.
• Limited scalability – not ideal for exploring many design alternatives quickly.

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Virtual Prototyping

• Creating digital simulations or CAD models, often with software tools (e.g., CAD, CAE, VR/AR).

Advantages

• Fast and flexible – easy to modify, duplicate, and iterate designs.
• Cost-effective – no need for materials or manufacturing until later stages.
• Simulation capabilities – can test stresses, aerodynamics, heat, etc., before real-world testing.
• Collaboration-friendly – designs can be shared digitally with teams worldwide.
• Explores more options – allows rapid testing of multiple variations.

Disadvantages

• Lacks realism – can’t fully replicate tactile, ergonomic, or aesthetic qualities.
• Simulation limitations – results may differ from real-world performance due to software assumptions.
• Requires expertise/software – needs skilled operators and access to advanced (often expensive) tools.
• May cause overconfidence – reliance on virtual results can hide issues that only physical testing would reveal.

Manufacturing Processes

Additive Manufacturing

• Additive manufacturing describes various processes where material is incrementally and accurately added by deposition of fine layers.
• Used to produced fully finished components and complex components
• Reduces material waste

Examples

• 3D printing is suited to prototyping
• Casting - More efficient than 3D printing
• Die casting and injection moulding

Subtractive Manufacturing

• A process where material is shaped and sized by controlled material removal
• Results in material waste

Examples

• Laser cutting
• Turning
• Drilling
• Milling
• Shaping
• Engraving