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Tag: project

Prototyping and testing

With an experienced, creative and multi-disciplinary team of engineers JOULEHUB supports companies in transforming an idea into an engineered concept, using the most advanced numerical codes and design tools.

Deliverables

We optimize product design by FEM (Finite Element Method), CFD (Computational Fluid Dynamics) analyses and virtual testing considering complex physical phenomena and advanced materials in the following fields:

  • structural mechanics (FEA)
  • vibrations and fatigue analysis
  • CFD
  • thermal management
  • impact and crash analyses
  • coupled multi-physics.

We use Life Cycle Thinking instruments to support you in strategic decisions including the assessment of economic and environmental impacts, paving the way for product certifications.

We support you by prototyping the developed design and testing it in a relevant environment, providing:

  • Rapid prototyping with 3D printing machines
  • Design of Experiment (DoE) to optimize test campaign
  • Material testing and prototyping (from laboratory scale to full scale)
  • Process development and validation (from laboratory scale to full scale)
  • Setup of demonstrator combining mechanical and mechatronic skills
  • Prototypes and small series production.

Contact us today to find out more.

How Rapid prototyping helps you Design and Develop Products quickly

Product design failure in the development stage is a huge loss for the organization in terms of man-hours and the money invested in the development process. A tangible prototype of the product makes the complex product design looks simple. It helps product designer and engineers in visualizing and analyzing the actual part of the product before the development stage. This drastically reduces the chances of product failure to a great extent.

It helps you to develop every component of the complicated product in stages and compare every part of it with the prototype prepared. Any deviation from the prototype can give you a clear indication of the design failure of the part and it helps the development team to rectify the error immediately.

Why Rapid Prototyping?

  1. Clear understanding and visualization of the Design Concepts
    It acts like a POC for the client and it’s easier to understand the design rather than struggling to visualize by looking the design on the screen or paper. It helps the designer to understand the look and feel of the design rather than having a virtual design through CAD model.
  2. Quick changes or modification
    Having a visible and tangible model provides manufacturers with the better understanding of how the product may look like. It helps them analyze the actual design and suggest correction or modifications quickly which can be incorporated to make the product design perfect before advancing to the manufacturing stage.
  3. Reduction in monetary investment and time consumption for Designing
    Rapid prototyping creates a model very similar to what an actual product can look like. This eliminates a need for preparing molds and use of other software to create a model. The existing CAD software and printing equipment are sufficient to create a rapid prototype which gives you a feel of an actual model. This not only result in saving of time and cost invested in creating the actual models but also results in overall reduction of your time to market.
  4. Product Customizations
    Rapid prototyping empowers you in developing the customized products with ease. A small modification in CAD model is sufficient to create a modification in the existing design without the need for any special tool or process.
  5. Higher Accuracy level in designing
    The material used for the prototyping has similar properties of the actual product. This makes it easier to perform the physical tests and identify the flaws and errors prior to the actual manufacturing process. This helps manufacturers to avoid the risk of halting the manufacturing process at a later stage.

Nowadays, manufacturers are more inclined towards rapid prototyping while initiating their new product development and manufacturing process. These revolutionary techniques are making things easier for product development companies, and product manufacturers in developing innovative products cost-effectively.

If you are struggling to hold the market share due to continuous innovative products being pumped by the competitors, there is a time to look into your product design and development process. Probably you require an expert who can boost your product development team to enable them to develop products at a faster pace.

At JOULEHUB, we carry out a systematic study of your concept and existing product line to redesign of systems and components successfully. We can partner with you to innovate, design and develop products rapidly to gain the first mover advantage.

JOULEHUB offers custom engineering design solutions and services to our global clients leveraging a team of experienced engineers and designers. Our diverse services span all aspects of engineering from legacy conversions, to designing and detailing, to FEA/CFD analysis. JOULEHUB has domain expertise in many industry verticals including automotive, off-highway vehicles, heavy machinery, consumer equipment, packaging and medical devices.

Contact us today to find out more.

Key Differences Between Production and Prototype Tooling

In product development, testing is a critical factor. In some cases engineers need to demonstrate how a new design will perform as part of management approval for investment into production. In other cases, regulatory requirements require testing of products from representative materials and processes that correspond to those intended. As part of its prototyping methodology, manufacturers often use different strategies for executing prototypes depending on the purpose of the parts. When injection molding is involved in the final product, the use of specially engineered polymers in the product specification may result in the need to injection mold the parts being used in testing in order to get reliable results. Depending on the circumstances, the final production injection molds may be used or separate prototype tooling may be utilized. The goal is to ensure a superior prototype and timely testing, which helps identify design changes before taking a product into full production.

There are a number of key decisions, which go into the prototype tooling process, which enables a design team to select the appropriate build strategy. A key element to consider is the degree of uncertainty or uniqueness of a particular design. The more unique a given design is from a company’s previous manufacturing experience, the more critical it is to test process and product early. Likewise, overall program schedule plays a big factor. The component in need of testing may just be one part of an overall system being developed. Final production tooling timing may be aligned more with the overall system’s development schedule. If so, waiting for production tooling may be a costly risk delaying valuable testing time. In those cases, a simple prototype tool to allow early evaluation of the component or sub-system may be a great investment. Finally, the likelihood a product may change should also be a factor in considering if separate prototype tooling should be used. If a design change is likely or probable, it is better to identify this early rather than executing the change to final production tooling which could require welding on the tool steel or other changes which might compromise the integrity of the mold for long run use.

For both production and prototyping, every tool is different. Two factors, which strongly influence the distinction between the two, are as follows:

  • Production Quantity – The degree of automation in a tool is often correlated with the production quantity intended. High production molds often are highly automated with wear maintenance provisions, sensing and process control capability built into the design. These factors add to the time and cost of the tooling but provide cost and processing efficiencies in the actual volume molding itself. Likewise high production molds are often multi-cavity allowing several parts of the same design to be molded simultaneously. Prototype molds by contrast, typically have limited automation and cavities, saving time and cost in fabrication and thus are suited to low volume molding with quicker development time.
  • Hard vs. Soft Tooling – Another difference between the prototype tooling process and production tooling process has to do with tooling materials. Production tooling is often made from hardened P20, H13 or other tool steel suitable for repeated use and long tool life. Heat-treating and surface hardening or plating are also often utilized. Prototype tools are often called soft tools based on the fact that aluminum and or mild steel are often used. This tooling material can be cut quicker in the machining process allowing for faster and more cost effective prototype tools. The tradeoff however is that tool life may be limited depending on the plastic intended to be molded and processing is not optimized for shortest cycle time. Soft tooling can offer affordability for both production and prototyping. However, because it allows for quick turnarounds of samples, it is often the preferred choice for prototypes.

Tooling is a big investment and cost is always an important deciding factor. Therefore, a manufacturing company will determine which type of tooling makes the most sense from a financial perspective and any product based factors necessary to make the right choice.

Innovative Prototyping and Production Services

The JouleHub team of experts can assist your team in the process of making critical decisions about machines, material, and tooling and providing the support services needed regardless of choice. For a superior quality prototype or product, we would love the opportunity to help. Visit us online or call to speak with a company representative regarding your project.

Mechspire is on Kickstarter

We have some exciting news here at JOULEHUB! For those of you who don’t already know, we have created a new machineries sharing portal called Mechspire. Mechspire is your go-to place for sharing industrial machines with your fellow businesses. You can list your own machines that you don’t use anymore or you can rent a machine you only need to use one time. We are very excited to share this portal with you! Here’s the catch- we’re still trying to get it off the ground.

We are only 85% complete so, we decided to launch a Kickstarter project! We need help finishing up all the technical aspects of our virtual portal so you can start taking advantage of renting machines without any complications.

Mechspire will help you save money. No more buying large, new machines that you only need for one project. Save your money and rent it from someone who lists it on Mechspire. Or, make the money back you spent on buying new machines by renting out yours! Our portal is already up if you want to get a gist for how it will work, but we need to reach our Kickstarter goal before people can start listing their machines.

So, if you are ready to start using Mechspire to save money and increase your industrial productivity, back our project today! We have some awesome rewards:

  • Pledge CHF 1 or more = Public thank you on the Mechspire website
  • Pledge CHF 5 or more = Public thank you on the Mechspire website and Facebook page
  • Pledge CHF 100 or more = Free registration and your first month of listings are free on our portal
  • Pledge CHF 5,000 or more = Dinner with the Mechspire founders team

Stay tuned and keep checking back on our Kickstarter page and all our social media accounts for weekly updates on how our Kickstarter is coming along!