Prototype Design & Engineering Verification

What is the best way to get a prototype for design and engineering verification? Early in the designing process, when the ideas are flowing freely, concept models are very helpful. As you progress with your project, a prototype design that has the size, finish, color, shape, strength, durability and material characteristics of the intended final product becomes increasingly important. Therefore, using the right design prototyping process is critical. In order to most effectively validate your creation, pay close attention to these three key elements: functionality, manufacturability and viability. This will ensure the best results and help you to develop further.

WayKen devote to prototype engineering, Provide prototyping and modelmaking for product design engineering, and silicone mold vacuum casting for plastic product design.

Concept Model

– A  Premier physical model made to demonstrate an idea.
Proof of concept prototype allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.

Important prototyping attributes:
Speed – turnaround time to convert a computer file into a physical prototype.
Appearance – any visual attribute – color, texture, size, shape, etc.

Assembly / Form Fit Test 

– making some or all of the parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2” spacing and the mating slots at 1” spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.

Important prototyping attributes:
Form – the shape of the part – features and size
Fit – how the part mates with other parts.

Functional Testing 

– seeing how a part or assembly will function when subjected to stresses representing what it will see in its actual application.

Important prototyping attributes:
Chemical Resistance – resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.
Mechanical Properties – strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.
Electrical Properties – interaction of electrical fields and the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistivity, static decay, etc.
Thermal Properties – Changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, vicat softening point, etc.
Optical – ability to transmit light. May include refractive index, transmittance and haze.

Life Test 

– testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g. temperature, humidity, voltage, UV, etc) to estimate in a shorter period of time, how the product will react over its expected life.

Important prototyping attributes:
Mechanical Properties – fatigue strength – ability to withstand large numbers of load cycles at various stress levels.
Aging Properties (UV, creep) – ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.

Regulatory Testing 

– testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as medical, food service or consumer application. Examples include UL, CSA, FDA, FCC, ISO ,EC.

Have an idea in mind? Contact us for more information – or request a quote and get started today.