Technical Prototyping

1. Protovation – Technical feasibility
Thomas J. Howard
https://sites.google.com/site/thomasjameshowardhomepage/
thow@mek.dtu.dk
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same licence and if including the following statement:
“Original material by Thomas J. Howard for course 42629 – Innovation and Product Development
Department of Mechanical Engineering, The Technical University of Denmark”

2. Rapid Prototyping Facilities
3 different kinds of machines:
1. A machine producing models in
plaster (not for functional tests).
This process is called ‘3D
Printing’ or 3DP.
2. A machine producing models from
fluid acrylic type of plastics. The
process is SLA-like, make very
small details in thin layers to 25
microns but is rather slow.
3. 2 machines producing models
from a plastic thread. They are
made from self-assembly kits and
are very cheap. The process is
called FDM (Fused Deposition
Modeling) and is rather fast
compared to the aforementioned
processes.
2 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

3. Manufacture and Fabrication Facilities
1. Produce and engineering drawings and 3d sketches of the parts
2. Print them out on paper and go to discuss with Jan Frank Pedersen at
the earliest opportunity.
3. Provide Jan with the files/drawings he requests and arrange with him a
schedule of work and your deadline.
3 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

4. 4 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

5. Paper prototyping
5 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

6. Proof of principle prototypes
Oversights revealed by the Prototypes
Concept 1 Concept 2 Concept 3
– Awkward assembly – Awkward assembly – Lock insecurity
revealed
– Very small increments – Cannot work in all – More flimsy than
for code orientations anticipated
– Code revealed under – To release bars must – Supporting pin are too
tube first be raised small
– More flimsy – Awkward to adjust code – Awkward to adjust code
– Lock insecurity – Lock insecurity + Simplicity realised
revealed revealed
+ More discreet than + More sturdy + Dimensionally suited
anticipated
+ An effective visual + Locks securely even
deterrent when code is <2mm out
6 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

7. Prototype vs Production Model
Prototype parts Extruded parts
Instead of using a T cutter to form the extra lip T cutter would
have been required
Mill Square then fasten will screws. for this section
7 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

8. Proof of principle/form prototype
8 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

9. Mk. 9
9 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

10. 10 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

11. Prototype for assembly
11 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

12. Prototype for assembly
12 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

13. Sun cream on demand
What would a prototype be
able to tell us about the
product (excluding the
market) ?
13 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

14. Protovate your product
Taking your own project
and your list of burning
questions, design at least
1 prototype and test for
the product’s function or
the production feasibility.
10mins
14 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark

15. Questions
?
15 Original material by Thomas J. Howard for course 42629 – Innovation and Product Development 2012
Department of Mechanical Engineering, The Technical University of Denmark