Short answer

Integrate rapid prototyping and physical material flow modelling early in the design process to evaluate multiple concepts before committing to expensive full-scale development.

Field: Modelling
Source: Journal of Engineering Design and Technology (2020)
Method: Case study
Evidence: Strong effect

Combining rapid prototyping with physical modelling of material flow allows for cost-effective and time-efficient evaluation of multiple design concepts in the early stages of complex product development. This modelling research insight is drawn from a 2020 study published in Journal of Engineering Design and Technology. Using Case study, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Integrate rapid prototyping and physical material flow modelling early in the design process to evaluate multiple concepts before committing to expensive full-scale development.

Study

ModellingHigh ImpactStrong effect

Set-based physical and rapid prototyping accelerates concept evaluation in complex product development

Journal of Engineering Design and Technology · 2020

Key Findings

01The combined method provided valuable insights into critical factors previously unknown.
02The approach facilitated concept exploration and selection, leading to a superior solution compared to the original design.
03This method is applicable when numerical approaches are insufficient and full-scale prototypes are costly or time-intensive.

Application

Design takeaway

Integrate rapid prototyping and physical material flow modelling early in the design process to evaluate multiple concepts before committing to expensive full-scale development.

How to apply

For a new product involving intricate material behaviour, create 3D printed models of different configurations and use a malleable substance (like clay or putty) to simulate the material's movement through the design.

Project actions

01When exploring multiple design options, consider using rapid prototyping for form and a tactile material to simulate function.
02Document the insights gained from each physical model and material flow simulation.

Method & Evidence

AimTo investigate the effectiveness of a set-based concept evaluation method combining rapid prototyping and physical modelling for new product development.

MethodCase study

ProcedureFour extruder concepts for a metal additive manufacturing process were modelled using rapid prototyping for plastic components and physical modelling with plasticine to simulate material flow. The selected concept was then verified at full scale.

ContextNew product development, specifically for a metal additive manufacturing process.

Variables

IVCombination of rapid prototyping and physical modelling (set-based evaluation).

DVQuality of design insights, concept selection effectiveness, final solution quality.

CVComplexity of the product being developed, cost and time constraints for prototyping.

Strengths & Limitations

Strengths

+Provides a practical, cost-effective method for evaluating complex concepts.
+Facilitates discovery of unforeseen design challenges and opportunities.

Limitations

The chosen simulation material may not perfectly replicate the properties of the actual material being used in the final product.

Reliability & validity

The validity of the findings relies on the accurate representation of material flow by the plasticine models and the subsequent full-scale verification. Reliability would be enhanced by repeating the process with different teams or on different complex product types.

Think critically

How might the choice of simulation material (e.g., plasticine) affect the validity of the findings when dealing with materials that have vastly different rheological properties?

Design Principles

"Iterative physical and digital modelling enhances early-stage concept validation for complex systems."

This approach enables design teams to explore a wider range of solutions and uncover critical design factors that might be missed with traditional methods. It's particularly useful when full-scale prototyping is prohibitively expensive or time-consuming.

What This Means for Your Design

You can test out lots of different ideas for a new product quickly and cheaply by making quick models with a 3D printer and then using playdough to see how materials would flow through them.

How to use in your project

1.Reference this study when justifying the use of physical modelling and rapid prototyping for concept evaluation in your design project.

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Quick Cite

Paragraph starter

The research by Blindheim et al. (2020) highlights the value of combining rapid prototyping with physical modelling for set-based concept evaluation. This approach allows for efficient exploration and validation of multiple design concepts, particularly for complex products where full-scale prototyping is impractical. By using rapid prototyping for form and a malleable material to simulate function, design teams can gain critical insights early in the development process, leading to more robust and innovative solutions.

Source

Journal of Engineering Design and Technology

Concept evaluation in new product development

journal · 2020

View source

Questions About This Research

What does the research say about set-based physical and rapid prototyping accelerates concept evaluation in complex product development?: Integrate rapid prototyping and physical material flow modelling early in the design process to evaluate multiple concepts before committing to expensive full-scale development. Evidence: Journal of Engineering Design and Technology (2020).
Why does "Set-based physical and rapid prototyping accelerates concept evaluation in complex product development" matter for design?: This approach enables design teams to explore a wider range of solutions and uncover critical design factors that might be missed with traditional methods. It's particularly useful when full-scale prototyping is prohibitively expensive or time-consuming.
How can designers apply this research?: Integrate rapid prototyping and physical material flow modelling early in the design process to evaluate multiple concepts before committing to expensive full-scale development.
What were the main findings?: The combined method provided valuable insights into critical factors previously unknown.. The approach facilitated concept exploration and selection, leading to a superior solution compared to the original design.. This method is applicable when numerical approaches are insufficient and full-scale prototypes are costly or time-intensive.
What research method was used?: Case study.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2020 journal from Journal of Engineering Design and Technology.
What should I do differently in my next project?: For a new product involving intricate material behaviour, create 3D printed models of different configurations and use a malleable substance (like clay or putty) to simulate the material's movement through the design.
What are the limitations?: The effectiveness may vary depending on the complexity of the material flow and the fidelity of the physical models.