A2.2 Prototyping Techniques

Introduction

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Prototyping allows designers to visualize and test their ideas before committing to final production. By creating physical or digital representations of their designs, designers can identify potential problems, gather user feedback, and make informed decisions about design features and functionality. This iterative process leads to the creation of more innovative, user-centered, and successful products.

Guiding Question

Why is it necessary for designers to prototype ideas as part of a design process?

Prototyping is a fundamental in the design process, involves creating tangible or digital representations of design concepts. This practice serves as a bridge between abstract ideas and concrete realities, enabling designers to test, refine, and validate their designs before committing to final production.

There are two primary types of prototyping: low-fidelity and high-fidelity. Low-fidelity prototypes, often created early in the design process, focus on capturing the essence of an idea without delving into intricate details. They are typically inexpensive and quick to produce, making them ideal for exploring different design concepts and gathering initial feedback. High-fidelity prototypes, on the other hand, closely resemble the final product in terms of appearance, functionality, and materials. While more time-consuming and resource-intensive to create, high-fidelity prototypes provide a more realistic representation of the design, allowing for thorough testing and evaluation.

In recent years, rapid prototyping technologies have revolutionized the design process by enabling designers to create physical prototypes quickly and efficiently. Methods such as stereolithography (SLA), fused deposition modeling (FDM), and selective laser sintering (SLS) have significantly reduced the time and cost associated with prototype production, facilitating more frequent iterations and enabling designers to gather valuable feedback from potential users and stakeholders.

By incorporating prototyping into the design process, designers can:

Test and validate design concepts: Prototypes provide a tangible representation of design ideas, allowing designers to identify potential issues or limitations before committing to final production.
Gather user feedback: Prototypes can be used to elicit feedback from potential users, helping designers understand their needs and preferences.
Iterate and refine designs: Prototyping enables designers to make informed design decisions and refine their concepts based on feedback and testing.
Communicate design ideas: Prototypes can be used to effectively communicate design concepts to stakeholders, facilitating collaboration and buy-in.

Prototyping is an essential practice for effective design. By creating tangible or digital representations of design concepts, designers can test, refine, and validate their ideas, ultimately leading to the creation of innovative and successful products.

Korean

프로토타이핑은 디자인 프로세스에서 근본적인 요소로서 디자인 개념의 유형 또는 디지털 표현을 만드는 것을 포함합니다. 이러한 실습은 추상적인 아이디어와 구체적인 현실 사이의 다리를 놓아 디자이너가 최종 생산에 착수하기 전에 디자인을 테스트, 개선 및 검증할 수 있도록 합니다.

프로토타이핑에는 로우 피델리티와 하이 피델리티의 두 가지 주요 유형이 있습니다. 디자인 프로세스 초기에 자주 만들어지는 로우 피델리티 프로토타입은 복잡한 세부 사항에 깊이 들어가지 않고 아이디어의 본질을 포착하는 데 중점을 둡니다. 이들은 일반적으로 비용이 저렴하고 빠르게 제작할 수 있으므로 다양한 디자인 개념을 탐색하고 초기 피드백을 수집하는 데 이상적입니다. 반면에 하이 피델리티 프로토타입은 외관, 기능 및 재료 측면에서 최종 제품과 매우 유사합니다. 제작하는 데 시간과 자원이 더 많이 소요되지만, 하이 피델리티 프로토타입은 디자인의 보다 사실적인 표현을 제공하여 철저한 테스트와 평가를 가능하게 합니다.

최근 몇 년 동안 급속한 프로토타이핑 기술은 디자이너가 CAD 모델을 기반으로 물리적 프로토타입을 신속하게 생성할 수 있도록 함으로써 설계 및 개발 주기를 크게 가속화했습니다. 스테레올리소그래피(SLA), 융합 적층 모델링(FDM), 선택적 레이저 소결(SLS)과 같은 기술은 프로토타입 제작과 관련된 시간과 비용을 크게 줄여 더 빈번한 반복을 촉진하고 디자이너가 잠재적 사용자와 이해 관계자로부터 귀중한 피드백을 수집할 수 있도록 합니다.

디자이너는 프로토타이핑을 디자인 프로세스에 통합함으로써 다음을 수행할 수 있습니다.

디자인 개념 테스트 및 검증: 프로토타입은 디자인 아이디어의 유형적 표현을 제공하여 디자이너가 최종 생산에 착수하기 전에 잠재적인 문제나 제한 사항을 식별할 수 있도록 합니다.
사용자 피드백 수집: 프로토타입은 잠재적 사용자로부터 피드백을 수집하는 데 사용되어 디자이너가 사용자의 요구와 선호도를 이해하는 데 도움이 됩니다.
디자인 반복 및 개선: 프로토타이핑을 통해 디자이너는 정보에 입각한 디자인 결정을 내리고 피드백과 테스트를 기반으로 개념을 개선할 수 있습니다.
디자인 아이디어 전달: 프로토타입은 이해 관계자에게 디자인 개념을 효과적으로 전달하여 협업과 지지를 촉진할 수 있습니다.

결론적으로, 프로토타이핑은 효과적인 디자인을 위한 필수적인 실습입니다. 디자인 개념의 유형 또는 디지털 표현을 만들어 디자이너는 아이디어를 테스트, 개선 및 검증할 수 있으며, 궁극적으로 혁신적이고 성공적인 제품을 만들 수 있습니다.

Chinese

原型设计是设计过程中的一个基本环节，涉及创建设计概念的有形或数字表达。这种实践在抽象想法和具体现实之间架起了一座桥梁，使设计师能够在投入最终生产之前测试、改进和验证他们的设计。

原型设计主要分为两种类型：低保真和高保真。设计过程早期通常创建的低保真原型侧重于捕捉想法的本质，而不深入研究复杂的细节。它们通常成本低廉且制作迅速，因此非常适合探索不同的设计概念和收集初步反馈。另一方面，高保真原型在外观、功能和材料方面与最终产品非常相似。虽然创建起来更耗时和资源密集，但高保真原型提供了更真实的设计表达，允许进行彻底的测试和评估。

近年来，快速原型制作技术通过使设计师能够基于CAD模型快速创建物理原型，大大加速了设计和开发周期。立体光刻（SLA）、熔融沉积建模（FDM）、选择性激光烧结（SLS）等技术大大减少了与原型制作相关的成本和时间，促进了更频繁的迭代，并使设计师能够从潜在用户和利益相关者那里收集宝贵的反馈。

设计师通过将原型制作整合到设计过程中，可以：

测试和验证设计概念：原型提供了设计想法的有形表达，使设计师能够在投入最终生产之前识别潜在问题或限制。
收集用户反馈：原型可用于收集潜在用户的反馈，帮助设计师了解用户的需求和偏好。
迭代和改进设计：原型制作使设计师能够做出基于反馈和测试的明智设计决策并改进概念。
传达设计理念：原型可用于有效地向利益相关者传达设计理念，促进协作和认可。

总之，原型制作是有效设计的必不可少实践。通过创建设计概念的有形或数字表示，设计师可以测试、改进和验证他们的想法，最终创造出创新且成功的产品。

2.2.1 There are two techniques used in iterative design and development: low fidelity and high fidelity.

Guidance: You should be able to explain the advantages and disadvantages of using low- and high-fidelity prototyping within a design process.

Image source: Wecreatefutres.com

Low Fidelity Prototypes

In product design, low fidelity prototypes are basic, physical representations of a product that focus on form, basic functionality, and user interaction without detailed aesthetics or final materials.

Advantages

Quick and inexpensive to produce
Encourages experimentation and iteration
Facilitates early user testing and feedback

Disadvantages

Limited representation of final aesthetics and materials
May not accurately represent weight or ergonomics

High Fidelity Prototypes

High fidelity prototypes in product design are refined physical models that closely resemble the final product in terms of materials, finish, functionality, and user experience.

Advantages

Accurate representation of the final product
Allows for precise ergonomic and usability testing
Effective for presenting to stakeholders and potential customers

Disadvantages

Time-consuming and expensive to produce
May limit flexibility for major design changes

Real-world example of low-fidelity prototyping

source: Wilkhahn via DesignMilk

A team designing a new ergonomic office chair might create rough foam core models to test different seat shapes and backrest angles. These simple prototypes allow designers to quickly iterate on the basic form and test user comfort without investing in expensive materials or manufacturing processes.

In the example above, Wilkham developed low fidelity protoypes of the seat and back to test ergonomics and form.

Real-world example of high-fidelity prototyping

source: Uniti One Concept

An automotive design team developing a new electric vehicle might create a full-scale, fully functional prototype using 3D printed parts, actual materials, and working electronics. This high fidelity prototype allows for comprehensive testing of ergonomics, aerodynamics, and user interface elements in real-world conditions.

In this example, the Uniti One desing team developed a fullscale prototype to test ideas and generate interest at car trade shows.

Role of low- and high-fidelity prototyping in product development

In physical product development, the process often involves a progression from low to high fidelity prototypes. In the examples below we can see the progression of development of the handle for the OXO Good Grips peeler.

Learn more about the role of prototyping in the OXO GoodGrips vegetable peeler case study

Concept Exploration

Designers might start with quick sketches and rough cardboard or foam models to explore overall form and basic functionality.

Refinement

As concepts are narrowed down, teams may create more detailed 3D printed models or CNC-machined prototypes to test specific features and ergonomics.

Final Validation

Highly refined prototypes using near-final materials and manufacturing processes are created to validate the design before full production.

2.2.2 Drawings, either manual or prepared using computer-aided design (CAD) software, are used to explore, refine and communicate ideas.

Guidance: You should be able to outline why designers use drawings to explore, refine and communicate ideas (including informal drawing techniques such as free-hand sketching and formal drawing techniques such as assembled drawing (isometric), orthographic projection and exploded drawings), the advantages and disadvantages of using informal and formal drawing processes, and understand how these techniques are used at different stages of design development.

Within the context of product design, it is helpful to think of purpose of drawings. Drawings will have different "looks" depending on their function and audience, and role in the design process.

2.2.2 Drawings

2.2.3 Prototypes can be developed in both physical and virtual (digital) form.

Guidance: You should be able to discuss the purpose of prototyping and how it is used in design and product development.

Prototyping is a crucial step in the design and development process, allowing designers to test and refine their ideas before committing to a final product. Prototypes can be created in both physical and virtual (digital) forms, each with its own advantages and disadvantages.

The primary purpose of prototyping is to identify and address potential issues early in the design process. By creating prototypes, designers can:

Test functionality: Ensure that the product works as intended.
Evaluate usability: Assess how easy the product is to use.
Gather feedback: Obtain feedback from users and stakeholders.
Identify design flaws: Discover and correct any design issues.
Reduce risks: Mitigate the risk of product failure.

Physical Prototyping

Physical prototypes are tangible representations of a product or feature, often created using materials like cardboard, plastic, or 3D printing. They offer a tactile experience that can help designers understand the product's dimensions, weight, and feel.

A designer might create a physical prototype of a new smartphone case to test its fit, durability, and comfort.

Different fidelities of prototypes of a Dyson hair dryer and a Dyson vacuum. Notice how the detail and refinement of the design increases with the level of fidelity.

source: Dyson Institute

Low-fidelity models are a conceptual representation analogous to an idea. They are not tangible or durable, but they do communicate basic information about form, shape, function, etc. Paper prototypes are a good example of low-fidelity prototypes

Mid-fidelity prototypes communicate more about an idea or concept. They may communicate some but not all of the functions of the design.

High-fidelity prototypes attempt to represent as close as possible the functionality of the final product. They are typically durable enough to be testable and used by the user group to gather usability data.

Advantages

Real-world experience: Physical prototypes allow users to interact with the product in a tangible way, providing valuable insights into its usability and functionality.
Sensory feedback: They provide sensory feedback, such as touch, weight, and sound, that can be difficult to simulate digitally.
Testing in context: Physical prototypes can be tested in real-world environments, helping to identify potential issues that might not be apparent in a digital simulation.

Disadvantages

Time-consuming: Creating physical prototypes can be time-consuming and resource-intensive.
Cost: They may require specialized materials and equipment.
Limited revisions: Once a physical prototype is created, it can be difficult to make significant changes.

Virtual Prototyping

Virtual prototypes are digital representations of a product or feature, often created using computer-aided design (CAD) software or 3D modeling tools. They can be interacted with through simulations or virtual reality experiences.

A team of designers might create a virtual prototype of a new car design to test its aerodynamics, ergonomics, and safety features.

Advantages

Rapid iteration: Virtual prototypes can be created and modified quickly, allowing for rapid experimentation and feedback.
Cost-effective: They require minimal materials and equipment.
Remote collaboration: Virtual prototypes can be shared and accessed remotely, facilitating collaboration among team members.

Disadvantages

Limited realism: Virtual prototypes may not accurately represent the final product's look and feel, especially in terms of tactile sensations.
Technical limitations: Some features or interactions may be difficult to simulate accurately in a digital environment.

2.2.4 Physical prototypes are used to test ideas and gather insights that inform the development of a product.

Guidance: You should be able to explain how and why designers use physical prototypes (including scale, aesthetics, materials, function and performance) to enhance the development towards a final product.

Physical prototypes play an important role in the design and development process, providing designers with invaluable insights that inform the final product. By creating physical representations of their ideas, designers can test concepts, gather feedback, and refine their designs.

Benefits of physical prototyping

Enhanced user experience: Physical prototypes provide a tangible experience that helps designers understand how users will interact with the product.
Early identification of issues: By testing prototypes, designers can identify and address potential problems early in the development process.
Improved decision-making: Physical prototypes provide concrete evidence that can inform design decisions and help to avoid costly mistakes.
Effective communication: Prototypes can be used to communicate design ideas to stakeholders and obtain valuable feedback.

2.2.4 Prototyping

2.2.5 CAD is used to create virtual prototypes to test ideas and gather insights that inform the development of a product.

Guidance: You should be able to explain how and why designers use virtual prototypes, including the use of surface and solid models, generative design, digital humans, motion capture, haptic technology, virtual reality (VR) or augmented reality (AR), and finite element analysis (FEA)

Computer-Aided Design (CAD) has revolutionized the product development process by enabling designers to create virtual prototypes. These digital representations allow for extensive testing, analysis, and refinement of ideas before physical prototyping begins.

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A2.2.5 CAD and virtual prototypes

2.2.6 Rapid prototyping is used to create physical prototypes quickly for potential users and design teams to interact with them and provide feedback to drive design development forward.

Guidance: You should be able to describe the advantages and disadvantages of why designers use rapid prototyping techniques, such as: stereolithography (SLA), fused deposition modelling (FDM) and selective laser sintering (SLS).

Rapid Prototyping (RP) is a manufacturing technique that enables the rapid production of physical models or prototypes directly from digital design files. By using additive processes, RP technology builds objects layer by layer, using materials such as plastics, powders, polymers, or metals. This approach offers some advantages over traditional manufacturing methods.

One of the primary benefits of RP is its speed and efficiency. Compared to traditional prototyping techniques, which can be time-consuming and expensive, RP allows for the rapid creation of physical models, facilitating iterative design and testing. This accelerated turnaround time can significantly reduce development cycles and time-to-market.

RP offers exceptional flexibility and customization capabilities. Unlike traditional methods that often require complex tooling and setup, RP can produce highly customized parts and products with minimal effort. This enables designers and engineers to explore various design iterations and create unique prototypes tailored to specific requirements.

RP is also characterized by its environmental benefits. As an additive process, RP minimizes waste by using only the necessary material to create the desired object. This contrasts with traditional subtractive methods, such as milling or machining, which can generate significant amounts of waste material.

Additional Resources

Design.BHA Elements of 3D Printing: A useful resource to understand some of the key aspects of 3D printing
Key considerations for designing for 3D printing

Design guidelines for various 3D printing processes:

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) is a 3D printing process that uses a laser to fuse powdered material into solid parts layer by layer. This method allows for the creation of complex geometries without the need for support structures.

Advantages

Complex Geometries: SLS can produce highly complex shapes that are difficult or impossible to achieve with traditional manufacturing methods.
No Support Structures Needed: Since the powder bed supports the part during printing, there is no need for additional support structures, reducing material waste.

Disadvantages

Higher Costs: SLS machines and materials tend to be more expensive than those used in SLA and FDM, which can be a barrier for smaller projects.
Surface Finish Quality: Parts produced by SLS often have a rougher surface finish compared to SLA, which may require additional finishing processes for aesthetic applications.

Real-World Examples

Aerospace Components: Companies like Boeing utilize SLS for creating lightweight yet strong components that meet stringent aerospace standards.
Medical Devices: SLS is used in the production of custom orthopedic implants that require precise fit and strength characteristics tailored to individual patients.

Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM) is a 3D printing technique that works by melting thermoplastic filament and extruding it layer by layer to build an object. This process allows for quick production of durable prototypes.

Advantages

Cost-Effective: FDM is generally less expensive than other rapid prototyping methods, making it accessible for startups and small businesses.
Wide Material Range: It supports various thermoplastics, allowing for prototypes with diverse mechanical properties.

Disadvantages

Lower Resolution: Compared to SLA, FDM typically produces lower-resolution parts with visible layer lines, which may not be suitable for high-fidelity prototypes.
Strength Limitations: The strength of FDM parts can vary depending on the material used and the print settings, potentially limiting their functional use.

Real-World Examples

Prosthetic Limbs: Companies like Open Bionics use FDM to produce custom prosthetic limbs tailored to individual patients, significantly reducing costs while improving quality of life.

Stereolithography (SLA)

Stereolithography (SLA) is a 3D printing technology that uses a laser to cure liquid resin into solid plastic, layer by layer. This method creates highly detailed and smooth prototypes.

Advantages

High Precision: SLA produces highly detailed and accurate prototypes, making it suitable for intricate designs.
Smooth Surface Finish: The layer-by-layer curing process results in a smooth surface finish, which is beneficial for aesthetic models and functional testing.

Disadvantages

Material Limitations: SLA primarily uses photopolymer resins, which may not be suitable for all applications. The mechanical properties of these materials can be inferior compared to other methods.
Post-Processing Requirements: Prototypes often require extensive post-processing to remove supports and cure the material, which can add time and cost.

Real-World Examples

Dental Models: SLA is widely used in dentistry to create precise dental models for crowns and bridges due to its high accuracy and smooth finish.
Consumer Electronics: Companies like Apple have utilized SLA for creating prototypes of their devices to evaluate form and fit before mass production.

Linking Questions

What ergonomic aspects should be considered when selecting prototyping techniques? (A1.1)
How are concept models used to generate user feedback in a user-centred design (UCD) approach? (B1.1)
Why are different prototyping techniques used as part of the design process? (B2.1)
How does a good understanding of prototyping techniques help designers approach modelling and prototyping of their potential design solutions? (B2.2)
How can prototyping techniques be used to evaluate the appropriateness of material selection? (B3.1)
To what extent can virtual prototypes and simulations model real-world situations involving structural, mechanical and electronic systems? (B3.2, B3.3, B3.4)

Linking questions are questions that help you connect different parts of your design technology studies. They can show how ideas and skills are related to each other.

Why are linking questions important?

Linking questions can help you:

Understand the big picture: See how different parts of design technology fit together.
Learn more: Connect new information to what you already know.
Show your knowledge: Demonstrate your understanding of design technology in a deeper way.

How can you use linking questions?

Connect subtopics: Find relationships between different parts of the course
Use your skills: Show how you can apply design technology skills in different areas.
Think about the nature of design technology: Consider the big ideas and principles that guide design technology.
Apply to the real world: See how design technology can be used in real-life situations.

Research and references

Booth, Bryce, et al. “Generative AI Fuels Creative Physical Product Design but Is No Magic Wand | McKinsey.” Www.mckinsey.com, www.mckinsey.com/capabilities/mckinsey-digital/our-insights/generative-ai-fuels-creative-physical-product-design-but-is-no-magic-wand.
Constantine, Stuart. “Generative Furniture N1 - Core77.” Core77, 6 Dec. 2021, www.core77.com/posts/110899/Generative-Furniture-n1. Accessed 19 Dec. 2024.
“Digital Human Models | the OPEN Design Lab.” The OPEN Design Lab, Pennsylvania State University, 28 Sept. 2017, www.openlab.psu.edu/project/digital-human-models/.
Formlabs. “Designing the Wheelchair of the Future with 3D Printing.” Formlabs, 2020, formlabs.com/asia/blog/3d-printed-wheelchair/. Accessed 19 Dec. 2024.
“Generative Design 101.” Formlabs, 2022, formlabs.com/asia/blog/generative-design/. Accessed 2022.
Madier, Dominique. “How Finite Element Analysis Is Useful in Your Development Process.” Www.linkedin.com, 6 Jan. 2021, www.linkedin.com/pulse/how-finite-element-analysis-can-help-you-why-useful-your-madier/.
Martinez, James . “Generative Design Chairs | Autodesk Community Gallery.” Autodesk Community Gallery, 2021, www.autodesk.com/community/gallery/project/157790/generative-design-chairs. Accessed 19 Dec. 2024.
Moran, Kate. “The Aesthetic-Usability Effect.” Nielsen Norman Group, 29 Jan. 2017, www.nngroup.com/articles/aesthetic-usability-effect/.
“What Are Some of the Best Practices and Tools for Creating and Testing Aesthetics in Product Design?” Www.linkedin.com, www.linkedin.com/advice/1/what-some-best-practices-tools-creating-testing-aesthetics.
“What Is a Haptic Feedback? | TESLASUIT Blog.” TESLASUIT, 30 May 2022, teslasuit.io/blog/haptic_feedback/.
Whitenton, Kathryn. “How to Test Visual Design.” Nielsen Norman Group, 17 June 2018, www.nngroup.com/articles/testing-visual-design/.

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