Virtual prototyping is a method in the process of product development. It involves using

computer-aided design Computer-aided design (CAD) is the use of computers (or ) to aid in the creation, modification, analysis, or optimization of a design. This software is used to increase the productivity of the designer, improve the quality of design, improve co ...

(CAD), computer-automated design (CAutoD) and

computer-aided engineering Computer-aided engineering (CAE) is the broad usage of computer software to aid in engineering analysis tasks. It includes , , , durability and optimization. It is included with computer-aided design (CAD) and computer-aided manufacturing (CAM) ...

(CAE) software to validate a design before committing to making a physical

prototype A prototype is an early sample, model, or release of a product built to test a concept or process. It is a term used in a variety of contexts, including semantics, design, electronics, and software programming. A prototype is generally used to ...

. This is done by creating (usually 3D) computer generated geometrical shapes (parts) and either combining them into an "assembly" and testing different mechanical motions, fit and function. The assembly or individual parts could be opened in CAE software to simulate the behavior of the product in the real world.

Background

The product design and development process used to rely primarily on engineers' experience and judgment in producing an initial concept design. A physical prototype was then constructed and tested in order to evaluate its performance. Without any way to evaluate its performance in advance, the initial prototype was highly unlikely to meet expectations. Engineers usually had to re-design the initial concept multiple times to address weaknesses that were revealed in physical testing.

Move towards virtual prototypes

Today, manufacturers are under pressure to reduce time to market and optimize products to higher levels of performance and reliability. A much higher number of products are being developed in the form of virtual prototypes in which engineering simulation software is used to predict performance prior to constructing physical prototypes. Engineers can quickly explore the performance of thousands of design alternatives without investing the time and money required to build physical prototypes. The ability to explore a wide range of design alternatives leads to improvements in performance and design quality. Yet the time required to bring the product to market is usually reduced substantially because virtual prototypes can be produced much faster than physical prototypes.

End-to-end prototyping

End-to-end prototyping accounts fully for how a product or a component is manufactured and assembled, and it links the consequences of those processes to performance. Early availability of such physically realistic virtual prototypes allows testing and performance confirmation to take place as design decisions are made; enabling the acceleration of the design activity and providing more insight on the relationship between manufacturing and performance than can be achieved by building and testing physical prototypes. The benefits include reduced costs in both design and manufacturing as physical prototyping and testing is dramatically reduced/eliminated and lean but robust manufacturing processes are selected.

Effects

The research firm Aberdeen Group reports that best-in-class manufacturers, who make extensive use of simulation early in the design process, hit revenue, cost, and launch date and quality targets for 86% or more of their products. Best-in-class manufacturers of the most complex products get to market 158 days earlier with $1.9 million lower costs than all other manufacturers. Best-in-class manufacturers of the simplest products get to market 21 days earlier with $21,000 fewer product development costs.

Examples

Fisker Automotive Fisker Automotive was an American company known for producing the Fisker Karma, which was one of the world's first production luxury plug-in hybrid electric vehicles. It debuted at the 2008 North American International Auto Show, and first ...

used virtual prototyping to design the rear structure and other areas of its Karma plug-in hybrid to ensure the integrity of the fuel tank in a rear end crash as required for

Federal Motor Vehicle Safety Standards The Federal Motor Vehicle Safety Standards (FMVSS) are U.S. federal vehicle regulations specifying design, construction, performance, and durability requirements for motor vehicles and regulated automobile safety-related components, systems, and ...

(FMVSS) 301 certification.

Agilent Technologies Agilent Technologies, Inc. is an American life sciences company that provides instruments, software, services, and consumables for the entire laboratory workflow. Its global headquarters is located in Santa Clara, California. Agilent was establi ...

used virtual prototyping to design cooling systems for the calibration head for a new high-speed

oscilloscope An oscilloscope (informally a scope) is a type of electronic test instrument that graphically displays varying electrical voltages as a two-dimensional plot of one or more signals as a function of time. The main purposes are to display repetiti ...

Miele Miele ( ; ) is a German manufacturer of high-end domestic appliances and commercial equipment, headquartered in Gütersloh, Ostwestfalen-Lippe. The company was founded in 1899 by Carl Miele and Reinhard Zinkann, and has always been a family-o ...

used virtual prototyping to improve the development of its washer-disinfector machines by simulating their operational characteristics early in the design cycle. Several CAE software solutions (for example, Working Model and SimWise) offer the possibility to check the benefits of virtual prototyping even for students and small companies, and collection of case studies are available since 1996.Lista Studio,
Lista Studio's Case Studies
.

References