Prototyping and Modelmaking for Product Design

Second Edition

Bjarki Hallgrimsson

• Publisher: Laurence King Publishing
• Year: 2012
• ISBN:
  9781780673868
• Topic: Design
• Subtopic: Product Design

Building prototypes and models is an essential component of any design activity. Modern product development is a multi-disciplinary effort that relies on prototyping in order to explore new ideas and test them sufficiently before they become actual products. Prototyping and Modelmaking for Product Designers illustrates how prototypes are used to help designers understand problems better, explore more imaginative solutions, investigate human interaction more fully and test functionality so as to de-risk the design process. Following an introduction on the purpose of prototyping, specific materials, tools and techniques are examined in detail, with step-by-step tutorials and industry examples of real and successful products illustrating how prototypes are used to help solve design problems. Workflow is also discussed, using a mixture of hands-on and digital tools. A comprehensive modern prototyping approach is crucial to making informed design decisions, and forms a strategic part of a successful designer's toolkit.

MODELMAKING

4 Principles and Choices for Modelmaking

5 Health and Safety

6 Space and Setup

7 Workflow

8 Tools

— Basic Hand Tools

— Power Tools and Machine Shop Tools

— Rapid Prototyping

— CNC Machining and Laser Cutting

9 Adhesives and Fillers

10 Paper

11 Foamcore

12 Polystyrene Foam

13 Thermoplastic Sheet and Extruded Shapes

14 Polyurethane Modeling Board

15 Wood

16 Modeling Clay

17 Casting

18 Painting: More than an Afterthought

19 Graphics: Labels and Decals

20 Softgoods: Sewn Textile Products

4

PRINCIPLES AND CHOICES FOR MODELMAKING

In order to build the right kind of model it helps first to consider the guiding principles that apply to any modelmaking effort. These will in turn help to guide the choices of materials as well as process.

Principles of Modelmaking

These principles are in essence the rules that one should try to consider before, and while, making the models. These help to keep the big picture in mind, which in turn will make the experience more effective, useful, and safe.

Health and Safety

Nothing is more important than safety. Please read Chapter 5 on health and safety (page 45) and never attempt to use any machine tools without the proper training and supervision. Always wear the appropriate safety clothing and equipment, read the instructions, and study the safety data sheets for materials.

Purpose

The model is built to serve the prototyping uses outlined in the Prototyping section of Chapters 1 to 3. Looks-like models will usually be built in a solid form. This means that since there are no internal functional parts, the model will not be cored out. This is faster and sufficient for the end purpose. Similarly, a prototype built for the purpose of testing a mechanical function can be made more easily by not worrying too much about the exterior appearance. It is therefore often more economical to build separate models to examine appearance versus function. This also requires some discipline. It is easy to get drawn into the temptation of building something that comes as close to the final product as possible, losing sight of the fact that the model was meant only to explore or test one aspect of the design.

Effectiveness

Models should be built in an effective way. It is useful to reflect on the requirements by asking some introspective questions. How precise does the model need to be? A lower level of precision may be faster and more economical, and acceptable for the intended purpose. Can the model serve several uses, or is it quicker and easier to build separate models to look at different issues? What is faster? What is easier to change? Also use the computer effectively. Is this the time to start designing the final product in 3D, or can the computer be used more efficiently as a tool for making templates for some quick handmade models?

Appropriateness

There is a difference between a model built for exploration and one built to persuade clients and investors about the value of a concept. The former can be rough and purposeful by virtue of its content, whereas the latter needs to be viewed in a formal light. Both models could be built to a low level of fidelity, but the workmanship and level of finish of a model for presentation to nondesigners generally needs to be perfect. To an outside eye, a model with exposed glue marks and poor workmanship might create an impression of lack of professionalism and credibility. On the other hand, a model being built for a presentation does not necessarily need to be painted and finished to the level of the final product, as this could create the impression that the design is further ahead than intended. The audience and venue are therefore important factors to be considered.

Choices to Consider

By considering and following the above guidelines you will be able to make better choices in both materials and process. There are always options when making a model and there is never going to be a single perfect right answer. The important thing is to think through your objectives and base your decisions on the guiding principles.

Materials

In prototypes, materials of mass production are typically substituted for simpler and easier-to-work-with materials and processes. This obviously has to be taken into consideration both functionally and visually. Simple materials such as foamcore and paper might be suitable for making explorative models that can be created safely and quickly. At some point these materials reach their potential, and the next iteration progresses to stronger and more exact materials. This does not mean that the material has to be exact in terms of the intended material of manufacture; a solid piece of high-density polyurethane foam can be finished and painted to look like an injection-molded part. Modelmaking materials often used in product design will be outlined in detail in the following chapters with step-by-step examples.

Another aspect of material selection is experimentation. In order to realize new design possibilities you need to try new things, including new materials. Relying solely on known materials will limit your design possibilities. The materials shown in this book serve as a basis for formal and functional exploration. It is important to complement this with explorations into new materials that need to be examined for their innovative virtues, such as sustainability.

Take some time to experiment with safer, water-based materials if you are still using solvent-based paints and fillers. You still need to understand how to identify chemical hazards that may be hidden in a water-based product (see Chapter 5, page 47).

Tools

Some materials are worked easily with hand tools, whereas others require power or machine tools. The use of machine tools requires proper training and professional supervision. Many design firms and other professional settings do not have such facilities. In practice, machined parts can therefore be subcontracted to modelmaking shops. The precision offered by mills and lathes is usually not required for quicker exploration work that forms the mainstay of in-house prototyping activity. Digital methods such as 3D printing are cleaner and safer alternatives to machining, and are increasingly commonplace in both schools and companies.

5

HEALTH AND SAFETY

Goal

Modelmaking has the potential to expose ...