This document discusses rapid prototyping of embedded systems. It defines rapid prototyping as quickly fabricating a scale model using CAD data or providing an early user experience. Rapid prototyping can help increase functionality and feedback earlier in the development process. It also allows for increased cost control and risk mitigation. The document then discusses building rapid prototypes using platform-based embedded systems and commercial or open source hardware and software. It emphasizes managing the rapid prototyping process and customer expectations to gain benefits while controlling risks and costs.

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Rapid Prototyping of Embedded Systems
for IPD
CONFIDENTIAL
Rudy Van Raemdonck
Coordinator Embedded Systems
rudy.vanraemdonck@verhaert.com
THEME 2: RISK MANAGEMENT IN INNOVATION

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CONFIDENTIAL
Rudy Van Raemdonck
Coordinator Embedded Systems
rudy.vanraemdonck@verhaert.com

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Cut Tangible
• Looks like real
• Works like real
• Experience like
real
Risk focus Early
• Rapid
prototyping
• Agile
Options
Risk based development principles

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What is Rapid Prototyping?

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Definition and scope
Classic definition
“Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or
assembly using three-dimensional computer aided design (CAD) data”
(Source: Wikipedia)
Output
• Mechanical part/assembly
Possible techniques
• 3D printer
• SLA (Stereo lithography)
• SLS (Selective Laser Sintering)
• Milling
• Extrusion

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Definition and scope (cont’d)
A more generic definition
“Rapid prototyping is a process to provide a relevant user experience of the final product in an early
stage”
(Source: Verhaert)
Possible techniques
• 3D CAD
• Simulation (thermal, structural, electrical, ...)
• Mechanical manufacturing techniques
• Combining electronic building blocks
• Software prototyping
Output
• Rendered picture
• Executable model
• Mock-up
• Functional demonstrator
• User interface graphics (on paper, on screen)

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The challenge of Embedded Systems development

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Market evolution

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A challenging job
How to
cope
with this?
Time
To
Market 
Complexity

Price 

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How can Rapid Prototyping help you?

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Increase functionality
Functionality Conventional approach
• Comprehensive Analysis
• Detailed design
• Proto manufacturing
• Preliminary testing
• Show first results
Rapid Prototype approach
• Quick design
• Assemble Rapid Prototype
• Show first results

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Get earlier feedback
Feedback Conventional approach
• Initial feedback based on paper ware
• Not easy to envisage for all stakeholders
Stakeholder feedback tends to be proportional
to the rate of change of perceived functionality.
Rapid Prototype approach
• Feedback based on tangible results
• Interactive
• Inspiring

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Increase cost control & risk control
Conventional approach
• Large budget spent before first results
• Iterating a design in a late stage is costly
Changes (conventional)
Rapid Prototype approach
• First results after relative small budget is
spent
• Reduced learning curve
• Detailed design phase can be shorter/more
efficient
• Better specification
• More built-up knowledge
• Potential re-use of parts of Rapid
Prototype
Changes (rapid proto)
Cost per change

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RP Enclosure
Enhance user experience (conventional approach)
Demonstrator
Works like real
Mockup
Looks like real
Mechanical
subsystem(s)
Embedded
Electronic
subsystem(s)
Embedded
Software
subsystem(s)
Demo
User
Interface
Enclosure
User
Interface
Mechanical
subsystem(s)
Embedded
Electronic
subsystem(s)
Embedded
Software
subsystem(s)
IPD Process
Final product

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RP Enclosure
Enhance user experience (Rapid Prototype approach)
Mockup
Looks like real
Demonstrator
Works like real
Rapid Prototype
Experience like real!
Mechanical
subsystem(s)
Embedded
Electronic
subsystem(s)
Embedded
Software
subsystem(s)
Demo
User
Interface
Enclosure
User
Interface
Mechanical
subsystem(s)
Embedded
Electronic
subsystem(s)
Embedded
Software
subsystem(s)
IPD Process
RP
User
Interface
RP Mechanical
subsystem(s)
RP Embedded
Electronic
subsystem(s)
RP Embedded
Software
subsystem(s)
Final product

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Building Rapid Prototypes of Embedded Systems

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Rapid proto(type)²s
Short time
to demo
Low budget Relevant
functionality
Adaptability Reuse for
other
purposes
Probability
of solution
Similar
product
++ ++ ++ -- -- --
Modified
product
+ + + - -- --
Platform
based
+ 0/+ + + ++ +
Custom
design
-- -- ++ ++ -- ++

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Platform based Embedded Systems for Rapid Prototyping
Source/Provider Pro Con
Commercial available NI, Advantech Proven
High Quality
Can be used as final
solution in some cases
Professional support
Cost
Vendor lock-in (not or
difficult to port)
Open source modular Hw/Sw community
initiatives
Independent
manufacturer (often in
close collaboration with
MCU chip manufacturer)
Low cost
Large community
Extensible (large
number of I/O modules
available)
Highly portable
(schematics and
software can be used in
final design)
Build quality wrt purpose
Support relies on
goodwill of community
MCU starter/dev kits MCU manufacturers Low cost Proprietary
Focused on MCU, less
on peripheral functions
and expansion
FPGA FPGA manufacturers Very high performance
Very high flexibility
Complex toolchain
Expensive
Needs further
integration (PCB)

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Examples of Rapid prototype platforms (cont’d)

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Examples of Rapid prototype platforms (cont’d)

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Verhaert Rapid Prototype showcase

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Rapid Prototyping as part of an agile IPD process
Intake
LEAFLET
DUMMY/RENDERING
FUNCTIONAL
DEMONSTRATOR
PROTOTYPE
INDUSTRIAL MODEL
Product management
Design strategy
Applied technology
Mech & embedded product
design & engineering
Industrialisation
ALPHA PRODUCTS
Validation
(feasible/usable/useful/desirable/allowable)
Customer/End users
Idea
Marketable product
Explore Create Propose
Integrated development cycle
Iteration
Rapid Prototyping
main operational field

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Delivering tangible outputs
Dummy
LEAFLET
DUMMY/
RENDERING
FUNCTIONAL
DEMONSTRATOR
PROTOTYPE
INDUSTRIAL
MODEL
Product management
Design strategy
Applied technology
Mech & embedded product
design & engineering
Industrialisation
ALPHA PRODUCTS
Mockup (3D print)
Functional demonstrator (based
on similar product)
Working demonstrator
(custom made)
Final product

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Real life examples
 Examples of breadboards used for Product Development @VERHAERT

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Managing Rapid Prototyping of Embedded Systems

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Managing the Development Process
Final
Product
Time
Perfor-
mance
Budget
?Rapid
prototype
Time
Perfor-
mance
Budget
• Early results lead to early feedback, and
sharper defined requirements
• Time spent on rapid prototyping should be
gained back during detailed design
• Only a fraction of the total project
budget can be made available
• Detailed design phase still to
come!
• Minimize design effort/use readily
available building blocks
• Not fully functional product
• Focus on functionality that
contributes most to user
perception
• Maximize valuable feedback

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Managing the Customer
RAPID
PROTOTYPE
ENHANCED
USER
EXPERIENCE
BENEFITS
• Fast result
• WOW effect
• Early and direct
interaction with
‘product’
• Involvement in IPD
process
• Customer intimacy
SIDE EFFECTS
• Simplified
impression of project
• Questions about
project budget
• Feature creep
• Seemingly less
progress during
detailed design
phase
Manage Customer Expectations

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Conclusion

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Benefits
1. Cope with high market demands (complexity, time to market, price)
2. Produce tangible results fast
3. Surprise your customer (wow-effect)
4. Deliver enhanced user experience
5. Get more/better feedback from stakeholders early in project
6. Make your IPD process more agile (multiple and fast iterations)
7. Better control over cost and risks
8. Improve efficiency/cut design time of detailed design phase
1. Choose Rapid Prototype platform in function of the purpose and the
final product
2. Manage Rapid Prototyping phase in a similar way as the whole
project (find appropriate balance between performance, budget and
planning)
3. Manage customer expectations
Considerations

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