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.

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Three Phases of prototyping

Prototyping involves more than just the creation of a tactile mockup. It’s both a proof of concept using off the shelf hardware mixed with DIY materials and a fully-functional product constructed of precision-crafted components.

For that reason, new product designs generally go through several prototype iterations before they are deemed ready for the production line. Whereas it’s common to think in terms of a single prototype, the process, in fact, typically results in the creation of multiple iterations.

Indeed, the design process can usually see as many as three to five different prototype phases, with a multitude of test units put through their paces.

To that end, we have partitioned the prototyping process into three classifications: what we’ll call the Alpha, Beta, and Pilot. While different product developers may use alternative terminology such as minimum viable product (MVP) and proof of concept (POC), these phases are fairly universal. Each phase represents a step forward along a product roadmap and corresponds to an increasing score along the Technology Readiness Level scale.

It should be noted, however, that the process itself is usually nonlinear in nature, as developers will occasionally use lessons learned in various test phases to go back and revisit earlier iterations. Depending on what stage along the process you are, the tools, methods, decisions and challenges will be different.

For the sake of clarity we’ve listed prototypes in succession; however, in some cases, prototypes may be developed anywhere along the product development timeline. It’s important to realize that developers design prototypes to match the manufacturing method, so depending on changes and differences it may be necessary to push forward prototypes concurrently.

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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.