Useful Stuff
Design Methodology
This
is
the
general
approach
that
we
use
on
new
product
developments.
In
this
particular
case
it
is
for
a
typical
mechanical
product.
It
is
assumed that the product brief is complete and that all the market and user research has been done. Some of the steps may be iterative.
Brainstorming
To generate a large range of concepts, including radical as well as obvious solutions.
Sketching
Hand sketches or basic CAD models are produced in order to explore in greater detail the ideas generated above.
Wish list
The ideas generated are scored against the clients requirements and the results used to shortlist the best concept ideas.
Shortlist
The
preferred
Concepts
are
modelled
in
3D
using
our
CAD
(computer
aided
design)
system.
This
allows
concepts
to
be
refined
and
mechanisms to be simulated quickly and economically, resulting in a larger number of alternative solutions that can be explored.
This reduces the need for physical modelling; therefore the chance of finding the optimum solution is greatly increased.
Prototypes
Functional,
full-sized
models
are
made
based
on
the
CAD
solutions
above.
These
are
used
to
evaluate
how
the
parts
and
mechanisms
work
and feel. Modelling a full-sized mechanism or product can highlight aspects that are not always apparent on the CAD system.
Master CAD Model
The preferred concept is refined, the parts detailed and a workable detailed CAD model is generated.
Detailing
Components
and
proposed
materials
are
explored
for
size,
strength/stiffness
etc.
Both
manual
analysis
and
CAD-based
analysis
(Finite
Element Analysis, Mouldflow, etc) may be used.
Supply Chain
Materials
and
process
suppliers
are
investigated
to
ascertain
availability,
quality
and
costing
information.
Input
from
our
strategic
partners
may be used at this stage.
Concept Testing
Test
rigs
are
built
after
optimisation
of
the
mechanical
concept.
These
will
be
able
to
take
real
loads;
they
verify
the
above
work
and
allow
for
final refinement and optimisation. They will be incorporated into usable products to assess the performance accurately in real situations.
Field Testing
Once
verified
for
basic
strength
and
function,
rigs
are
also
tested
with
a
variety
of
potential
users;
feedback
at
this
stage
is
vital.
Test
houses
are also used to check performance independently and to ensure compliance with various standards.
User Trials
Market
and
user
research
is
carried
out.
Until
the
design
is
frozen,
it
is
subject
to
intensive
rounds
of
improvements.
At
this
stage
patents
are
usually finalised and applications made.
Supply Chain
Key suppliers are finalised and the design is detailed according to their processes.
Tooling
Where
possible
the
CAD
data
used
throughout
the
development
process
is
also
used
for
tooling
and
creating
tolerance
manufacturing
drawings, material specifications etc.
Technical Support
Involvement continues until beyond product launch, as much information has to be documented and passed on to the
Manufacturers, assemblers and the client as a whole.