Design & Engineering Verification
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Design & Engineering Verification

Prototyping and low-volume manufacturing are key steps in engineering and design validation. They help you extend your proof-of-concept model to high-quality engineering prototypes and pre-production samples that simulate the final product, and guide mass production through a series of validation phases.

WayKen offers a comprehensive manufacturing service that helps designers and engineers create test parts faster than ever before, and quickly iterate their designs according to actual testing and feedback to meet the required performance, verification, testing, certification and quality requirements.

USE ENGINEERING PROTOTYPES TO ENSURE YOUR PRODUCTS ARE DESIGNED FOR MANUFACTURING

Boost Your Confidence Through Verification Testing

As product development moves into the subsequent stages, it is increasingly important to conduct product verification testing programs that provide test and analysis results.

Engineering and design verification tests are specific product verification tests performed on engineering prototypes or pre-production components. They can verify whether the design meets the expected product specifications and performance, which including basic functional testing, manufacturing processes, performance parametric measurements and certification standards verification.

As the validation phase moves from engineering prototype through engineering validation (EVT), design validation (DVT), and production validation (PVT), each phase focuses on optimizing design and production. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability and viability.

Building Engineering Prototypes May Be Your Best Solution

It is typically prudent to consider the validation standards or validation paths for your product early in the development process. When the time and cost of making design changes have become increasingly demanding, creating high-fidelity engineering prototypes that accurately represent the final product, makes it easier to verify design, engineering, and manufacturability, before investing in expensive tools and putting them into production.

These functional and highly accurate engineering prototypes or pre-production prototypes commonly incorporate a range of components and moving mechanical parts. The most appropriate and efficient method of creating various components in terms of process and materials will be evaluated to ensure that the finished prototype accurately simulates the end-use product. It allows you to perform rigorous testing and verification before delivering your design to manufacturing.

Prototyping Partner For Your Engineering/Design Verification

With more than 20 years of engineering and model making expertise, WayKen thrives in technically challenging projects for prototype engineering.

We design the rapid solution for development project to bring your product to the final test validation phase. We can use our technical experience in high-precision CNC machining, prototype bridge tooling and rapid injection molding, provide the best advice on components according to materials, processes, tolerances, and predict potential problems to help tackle your engineering difficulties.

With professional engineers and project managers, WayKen is unparalleled in product prototyping and always maintains seamless collaboration with customers, able to provide ongoing support throughout the product development.

VERIFICATION IS A PROGRESSIVELY RIGOROUS PROCESS

Engineering Verification Tests (EVT)

What the EVT build makes is a engineering prototype by CNC machining, vacuum casting, or bridge tooling. It requires production intent materials and manufacturing processes whenever possible. But the 3D printing parts cannot be applied to the EVT.

  • Typically 20–100 units
  • Units must be fully functional and testable
  • Use tighter tolerances to meet test performance specifications
  • Test data is reviewed to ensure that the required performance is achieved, basic tests including power, thermal, and EMI
  • Uncover high impact design weaknesses and recommend potential changes to improve the product
  • It’s common to do a second EVT build after changes have been made.

Design Validation Testing (DVT)

The DVT builds include final versions of all components and design elements as much as possible. It validates the manufacturing process of the products through manufacturing sites in low-volume runs. Typically pre-production components are made from rapid injection molding or low-volume manufacturing and follow the production procedures.

  • Typically 100–1000 units
  • All parts should be from mold tools or pre-production processes
  • Ensure that products meet the requirements in terms of cosmetics and environment
  • The test programme is comprehensive, covering all the clauses of the relevant standards
  • Require fast failure analysis and corrective actions
  • Verify product certifications and standards in different countries or regions.

Production Validation Testing (PVT)

The production validation phase is the first official production run. You will establish a pilot production line to check if there is any failure at any stage of the production line and you will evaluate how to optimise the process.

  • Typically 500–2000 units, or even more
  • DFM (Design For Manufacturing) has been done and the molds are ready, no changes made to tooling
  • If all goes well, all units are intended to be sold to customers
  • Verify mass production (yield, quantity, time, rework time, etc.)
  • Full line setup and training procedures in place
  • The quality assurance (QA) and quality control (QC) procedures must be developed and tested
  • So far, the most exciting part of the PVT phase is waiting for feedback from your first users.

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