2.4.2 Development, Testing and Evaluation

Development of ideas

The often long and laborious process of taking an initial design to a final product or prototype is the development stage.

During this process the product may become more stylised and complex but, conversely, time or financial constraints may restrict how far it can be developed. 

Some believe that a good designer develops the product into something simple and elegant rather than complex - This could certainly be considered true of many Apple products where the complex hardware and software running the device is cleverly hidden behind a simple, attractive and intuitive interface. 

The methods used for product development are many and varied but in the next section we will look at a few of the more commonly used techniques.

Sketching and drawing

The most long standing, traditional and still most effective means of communicating designs ideas is through drawing with a pen or pencil. Despite advances in 3D CAD packages and vector drawing software, traditional drawing skills are still considered an important skill for a designer.

Physical modelling

Physical modelling is an essential tool used in developing ideas and a final prototype. Models can be as simple as a cardboard ‘mock up’ or one that resembles the final product.

CAD modelling

CAD Modelling is an essential tool used in developing ideas and a final prototype. The advantages of CAD modelling were discussed in Unit 1.7.

Product Rendering

As designs become more detailed, sketches will give way to rendering using a combination of thick and thin lines as well as colour tone and texture. These help to convey the design intent in more detail without having to make a model or prototype.

Augmented reality

Augmented reality (AR) is a technology that allows users to view and interact with virtual objects and information in the real world. It involves overlaying digital content and information on top of the user's view of the physical world. AR can be accessed through a variety of devices, including smartphones, tablets, and specialized glasses.

One of the main benefits of AR as a tool for product development is its ability to allow designers and developers to visualize and test products in a realistic and interactive way. For example, an automotive engineer might use AR to visualize how a new car design will look and function in the real world, or a furniture designer might use AR to help customers visualize how a new piece of furniture will look in their home before they make a purchase.

AR has the potential to significantly improve the product development and sales process by providing a more immersive and interactive way to visualize and experience products.

Planning

The success of a project is dependent on careful planning and preparation. There are various ways in which a designer might produce a plan:

• a Gannt chart to plan the time allowed for each stage of the design project in order to meet a given deadline

• planning the stages of manufacture of a prototype outcome

• sequencing the stages of manufacture with time ‘built in’ for checking and quality control.

• planning the production of components or sub-assemblies

• scheduling materials and parts to arrive ‘just in time’

• planning the sequence of designing to involve third parties such as model makers, prototyping etc.

Planning for commercial manufacture

Prototyping

If you are planning to make a batch or mass produced item you are likely to make a prototype which may be non working or fully functional depending on the project. 

In D&T, you are often designing a one-off or batch produced item so your finished project is essentially a prototype. 

In the car industry a prototype could be a multi-million pound fully functioning vehicle which will be tested to destruction before being put into production.

Evaluation and testing

Evaluation and testing should be seen as an ongoing activity all the way through the design process. For example:

• after completing initial investigation work, evaluate the data and material collected

• after completing initial ideas (and discussing with your client), evaluate the potential of the various ideas for development

• when a design proposal is produced, high quality CAD renderings or concept models should be shared with the client and evaluated before planning for production

• when prototypes are made, they can be tested and evaluated against the original design intention ( and product design specification)

• before a final prototype is made, the materials, construction details and methods of manufacture can be evaluated to see if there is a better or more efficient method of manufacture (see Generative design in Unit 1.7)

Prototype development has been covered in more detail in the various units and extra presentations EX2 and EX3.

Roles in the design process

Relationship between user, designer and maker 

The design process, along with consumerism, has advanced radically over the decades and is now a more complex process than simply making a bookcase to store books. The user was often an afterthought once a product had been developed but nowadays the user is an important factor in the design or products (see UCD).

Few products are sold direct to the public with most going through distributors who in turn sell to retail outlets. For a products to sell well it is important that it meets the needs of the client who, in turn, should have considered how it will meet the needs of the consumer.

Designers have the important task of bridging the two; they must create products that will solve the problem and appeal to the market, keep the client happy and ultimately sell well to make money. They need to consider also how it will be manufactured and marketed, so they really do have an important role.

Client / user

This is an individual or company that instigates the project, usually by providing a design brief. They will have identified a need, spotted a gap in the market or identified a creative or opportunity. They could be entrepreneurs seeking to make money by launching a new product or managers of existing manufacturing companies.

The designer

The person, usually a specialist, who will work with the client to produce a solution to their problem. Working with the client, they will produce or agree a design brief. Alternatively, they may be a designer/maker or inventor who produce their own design brief and develop a product to sell to other companies or market themselves. In larger companies the designer might have a specific role within a much larger design department. In car design, for example, one person might simply be designing one of the headlights.

Maker

A person or company that manufacture the products that have been designed. This may be a subsidiary company such as a manufacturing plant or it may be part of the company. It may also be an individual or small group of craftsmen or engineers. Rapid prototyping and modern manufacturing are blurring the lines between the different types of production.

Market/Users

The individual or group who will make use of the product developed by the designer and made by the manufacturer. Essentially, this is the consumer.

This simple four-part scenario best describes the roles found in industrial scales of production such as mass and continuous. For smaller scales the roles may be shared for example a designer/maker will design and make the product while the client may also be the user.

As well as these key roles there are many other roles to consider in the design and manufacturing process.

The Design Process

While there are various ways of working through the design process ther eare generally considered to be three main approaches:

• Empirical design is a trial and error approach. James Dyson made over 600 models and prototypes until he was satisfied with a solution that would work.

• Intuitive design is when you design from past experience. Chefs are very intuitive as are design specialists.

• Systematic design was the process most often used in schools and colleges where pupils break down their project into a series of stages or criteria they need to achieve in order to proceed through the design process. However, this is now considered an ‘outdated’ approach and they are encouraged to take a more iterative approach to design.

There is no best method, design is not a linear process and it is likely that a combination of all of the above would be used at some point in an industrial setting.

The design process

Commercial and economics reasons drive most inventions if they are not humanitarian. Most inventions are from designers/inventors who create for one of several reasons:

• they are dissatisfied with an existing products

• they want to make money

• they want to help others

• they are interested in a new material development or process created through scientific development

To Make Money

K.C Gillette designed the first disposable razor in 1903 after realising that the blade was the important part and needed regular sharpening or replacing. The disposable razor market is now worth several billion dollars annually.

King Camp Gillette was an American inventor and businessman who is best known for inventing the disposable razor. Gillette's disposable razor, which was first introduced in 1903, revolutionized the way that people shaved. Prior to the invention of the disposable razor, most people used straight razors, which required regular honing and stropping to keep them sharp. The disposable razor, on the other hand, was designed to be used once and then discarded, making it much more convenient and hygienic than traditional razors. Gillette's disposable razor was an immediate success, and the company that he founded, Gillette Razor company, went on to become one of the largest and most successful personal care companies in the world.

Wanting to help others

After watching a documentary about the spread of Aids in 1991, Trevor Bayliss heard that poor people were unaware of the news and messages about safe sex. This was due to having no batteries to power radios. He invented the Freeplay wind up radio as a result; 30 seconds of winding provided 30 minutes of power. The patented technology has now been incorporated into a range of products.

Scientific development

After WW2, two scientists working at Bell Labs in the US were experimenting using microwaves to study molecular structures. While experimenting with optics and infrared, they created the first laser which is short for light amplification by stimulated emissions of radiation. They never considered the commercial applications for lasers which today are used for eye surgery and cutting materials as well as barcode scanners and optics for CD, DVD and Blu Ray.

Summary

There are various approaches to the design process but it is accepted that, for students, it will usually start with a problem or design brief and end in a prototype outcome. However, the design process should not be seen as linear, it is a cyclic process that will involve several iterations of design ideas.

Planning and preparation are key to the success of a design project.

Students are encouraged to take an iterative approach to design which involves realising and testing several concepts before a final prototype is manufactured.

When designing, you should avoid ‘design fixation’ where you become fixated on just one idea which can stop you exploring creative ideas and taking creative risks.

Revision Notes

Much of this section will be completed as part of your NEA, but it is worth revisiting to check your progress, and it will also be addressed in the examination.

In particular, you should take an iterative approach to design and expect to produce several iterations in model or prototype form before you reach the final ‘prototype’ outcome for your design ideas.

Try to avoid design fixation. You may have a good idea, but there may well be better ideas to be developed. Take creative risks and try new ideas. You can always go back to the original concept if it doesn’t work out but you will be rewarded for taking the risk!

Consider collaborative work in the early stages of the project to generate ideas, especially with your client. However, you cannot collaborate on the project itself as it needs to be your own design work that is assessed.