Concept Generation
The first phase usually begins with an idea for a new
product. A product specification is developed to define the
functions and performance criteria for the
product. Depending upon the product, one or more industrial
design concept sketches are created to define the visual
appearance features.
Detail Design
The second phase is to develop a design based upon the concept
model and specification. The design is developed using
either Pro/Engineer or SolidWorks which are three-dimensional CAD
programs. CAD models are created for the individual parts
and for the assemblies which show how the parts go together (see
examples).
This virtual prototyping allows for interference checking and
range-of-motion studies before any physical parts are made. The
CAD models are built to be robust to ensure minimal impact by
downstream revisions. Parts are designed with consideration to how
they will be manufactured, assembled, and used.
Analysis
As the physical shape is being developed, the design is evaluated
from an analytical standpoint to ensure there will not be any
performance issues. The analysis to be performed varies
depending what is being designed, but may include things such as
stress or thermal analysis. These can be hand-calculations,
or if needed, FEA.
Prototype
Once the design is completed, prototypes can be
built. Plastic injection molded parts can be quickly
simulated by stereolithography (SLA) or other means. If
multiple parts are required, a silicon mold can be made and
urethane cast parts can be made. For fabricated parts,
detail drawings are created and sent to machine shops.
Assemble and Test
Component parts are assembled and tested to ensure the product
meets the performance specification. If changes are
required, the CAD models are updated and the prototype phase is
repeated.
Product Release
The final phase is to release the product for production. A
documentation package is delivered which includes detail drawings
of custom components and assembly drawings with bill of
materials. For tooled parts, CAD data can be exported
in a variety of formats to enable tooling directly from the CAD
database to ensure accuracy and expedite the tooling process.
