Analysis and Product Sketches

1.Product analysis:

Discussion over the priorities set in the project and the desired product, after completion of all project process stages of “Product Design & Development”. Discussion and analysis of product characteristics – technical, marketing and economic characteristics of the project. Basic analysis of competing products and matching them to the specific product idea, using comparison tables and systematization of features. Analysis of the market niche and market segmentation – forming a social and psychological profile of the type of customer, discussing other target groups of users, building a direction for possible development of a product range, etc. Discuss the merchandising strategy and its main priorities. Research and analysis for available intellectual property (invention, utility model or industrial design) possibly owned by competing products or ideas and designs that have not been implemented in the market. The basic information with which the compilation of the product analysis should be started is provided by the client – team, firm, company, etc. – to the contractor. The consolidation of all information and its completion in the form of a final product analysis, which will help to build a conceptual development, will be carried out between the two parties – the client and the contractor (designer and developer and consultant).

2.Development of concepts:

Concepts are developed to lay the foundations of the project. The substage is not limited to a number of concepts, as it aims to search and determine the direction of development for the whole project. During the development stage, the designer makes decisions on what the number of concepts will be. The aim is to extract the essence and to lay the basis of the product – at the following substages to to develop structure, functionality and styling. After the completion of the concepts, a view, analysis and selection of selected conceptual options for subsequent development are carried out. Every single concept is discussed, before choosing the right options with potential opportunities for further development.

3.Development of selected concepts:

The development of selected concepts is the substage, where several of the best concepts resulting from a previous substage – “Development of Concepts “, have to be selected. They have been selected after a view, analysis and careful selection from all concept designs, only then it sounds more rational. Mainly, four concepts are selected and undergo a development process. This is followed by a view, analysis and selection of two competing designs for subsequent development.

4.Development of two main designs:

Intensive development of the two main designs is done to develop variants of the structure, components and some basic details. Both designs evolve in a direction to show their main features. Their development must create a competitive choice in every aspect. After detailed development of the two designs, a view, discussion and selection of the main design are made. All this contributes significantly for the qualitative choice of the main design. All the efforts will be focused on the main design during the last substage.

5.Development of main design:

The development of the main design is the last and final substage of stage – Conceptual development. The design is developed, where the focus is over its composing elements –  the main structure, all the components, details and elements. The overall structure is developed and finalized – the functional characteristics are developed, the basic ergonomic zones are specified, the basic components and the details are made; the visual characteristics of the styling, etc. are improved. Often in the product sketches of the main design, as well as in some of the above subtopics, text is used – words, short descriptions and explanations related to technical and visual characteristics that contribute to the further development of the project. Upon completion of the development, a review, thorough analysis and discussion is performed before moving to Stage: “3D Modeling”. Only after approval by both parties – a client and a designer – are finalized Stage: “Conceptual Development” and will be transferred to Stage: “3D Modeling”.

Important:

Prior starting the project process – “Product Design & Development”, the client have to state what other potential participants in the project will be – team, partners and potential specialists, participating in the main communication and feedback during the discussion of each stage and substage. The transition from one stage to the next stage, as well as the successive completion and closure of each substage, will take place after a basic view, analysis, discussion and approval between the two parties involved in the project – designer and client. The stage is developed using product sketches. The stage is developed with product sketches – spatial structures, axonometric projections, structural sections, and more. The development is done with the purpose of laying the conceptual foundations of the product, developing a structure and characteristic styling, building the basic technical characteristics, creating a product identity, etc. At stage “Conceptual Development”, it is possible to make changes – partial or complete, in the direction of optimization, improvement and development of the overall concept of the product.

3D Model

1.Dimensioning the design:

Dimensioning and adapting the main design from the product sketches before moving to designing the main 3D model. If necessary, further development of the structure, components and details of the design is made, by using additional sketches in order to dimension and scale the geometry of the design. The design parameters are specified, including the main, as well as some detailed dimensions, before moving to 3D modeling.

2.Modeling the design:

A process of modeling of the main design is performed – 3D model. The development proceeds in stages, because 2D graphic images are adapted in the form of a 3D model. That changes the perception for the main design from the product sketches – design’s structure, components, details, shape, etc. During the modeling process, variants and combinations of the main structure and components are designed. All the main features that make up the 3D model – styling, overall structure, components and functional areas – are specified. During the modeling process of the main design, the basic technical characteristics that are part of the project are taken under consideration.

3.Detailed development:

Overview and analysis of the overall design structure before starting a detailed development. Emphasis is placed on the design of each component, separate detail and element. Detailed modeling and refinement of structure, functionality and vision. This substаgе is slow process, because many changes and modifications are made. This is made for the purpose of specifying and completing functional areas and shape, etc., all that builds the overall design.

4.Final development of the design:

Final design development and its components and details. The structure is assembled from the components and design details, after that re-viewing and detailed analysis. If necessary, the structure and all components and details are adjusted. The complete structure and details are synchronized, so that they are transformed into a harmonically projected design – in the form of an assembled 3D model. Everything that has been missed in previous substages is being discussed and overworked. This is a substage, where all the design features are finalized and refined, till reaching the final structure.

5.Preparation of 3D files:

The main structure, the components, the details and the design elements are recorded in the form of specialized file extensions. They have been used for different purposes: presentation; testing; manufacturing technologies for production of models and prototypes; mold tooling manufacturing; adaptation and manufacturing implementation, etc. Each of the designed components and details, which are forming the structure of the main design, are adapted and prepared in the form of 3D files. They contribute to product development in the next major stages of the design process – Stage: “Models and Prototypes” and Stage: “Adaptation of Manufacturing”.

Important:

Тhe designed 3D models and related files are needed both – in presenting, presenting and developing marketing, as well as in communication and consultations with subcontractors and manufacturers in the next two stages – Stage: “Models and Prototypes” and Stage: “Adaptation of Manufacturing”. Only after having the 3D models, you can obtain the approximate production cost for the relevant stages. When submitting the 3D models and specific types of file extensions to subcontractors and manufacturers, we receive price quotations and information related to manufacturing technology and used materials. With the designed 3D objects and their files, real production costs can be reached, necessary for model making, prototypes, products and mold tooling. Depending on the type of file extension, it is possible to be used for different types  manufacturing technologies, machines and materials, for example: 3D Printing; Multi-Axis CNC Milling Machines; CNC Milling Robots; Laser cutting, CNC router; 3D Bending and more. For models, matrix molds and mold tooling: composite mold and model – contact molding or vacuum infusion process; mold tooling – cold casting; mold tooling – pressure casting; plastic injection molds; stamping molds; cast models – metal casting process, etc. All this contributes for the main adaptation and implementation of the product in manufacturing – whole articles, components, details, elements etc.

Main Models, Scale Models, Test Components and Main Prototype

1.Plan of models and prototypes:

Analysis of Stage: “3D Modeling” and building a master plan for modeling and prototyping. The required number and type of products are specified in compliance with the set objectives and priorities of the project. The basic functional characteristics that are embedded in the product are taken under consideration, and the direction to follow is then determined until a particular end result is achieved. The appropriate types of models and prototypes are selected: mockups and product models for viewing and presentation; experimental models and products – for testing and data collection; making a basic prototype and setting a certain level of functionality or lack of functionality. The amount of models and prototypes, that have to be produced can not be accurately determined due to the specifics of Stage: “Models and Prototypes”. It is possible to make new models and prototypes, or different components and details, in order to clear the ambiguities and improve the final result. All these processes are undertaken with a constructive purpose in the direction of optimization of the structure, specification of the functionality, adaptation to the engineering characteristics of the project, etc.

2.Manufacturing technologies and materials:

Analysis and selection of model and prototype technologies and materials relevant to the specific project. After the selection of model and prototype technologies, communication with different subcontractors is carried out. Тhe technical characteristics, production requirements and used materials are specified. The production cost for each particular product is determined.This will also determine the total production cost of each model and prototype. Discussion over the technical characteristics, which have to be covered by the 3D models is held – necessary for manufacturing of models and prototypes. The appropriate subcontractors are selected for further partnership with and communication – production of models and prototypes.

3.Development of models and prototypes:

Development of selected types of models and prototypes – mockups, product models,  experimental models and main prototype. The designed 3D files from Stage: “3D Modeling” are used to get bids with price values. Subcontracting is underway and all possibilities and ways of making the respective models and prototypes are discussed. In the process of production, it is very important to have the feedback between the subcontractors, the client and the designer. Intense communication and discussion is necessary because various problems and obstacles of all kinds arise during the production process. All of this is part of the logical process of developing models and prototypes, with the aim to reach optimal end result. Before and during the production process, some corrections are made in the 3D files, from Stage: “3D Modeling”- regardless of the corrections of the main structure, components, zones or individual details. This is made with the aim to adapt the models and prototypes to the production requirements and the types of materials used. After the production of all models and prototypes a thorough examination, main analysis and discussion is carried out. If necessary, additional parts, details or new models and prototypes are produced.

4.Development of main prototype:

Final development and building of the main prototype. Selection of appropriate production technologies and a combination of materials is carried out. The main prototype emphasizes on the technical features such as – structure, vision and functionality. The functionality in the prototype is determined individually for each project – lack of functionality, partial functionality or close to the real functionality of the product. It is desirable, the technical characteristics of the product to reach level of identity 50%, exceeding over that percentage will be advantage for the stage of the project. Reaching certain levels of identity in the prototype is strictly individual for each particular project. In order to optimize the main prototype during its production, it is possible to make further adjustments and corrections of the 3D files – main structure, components or details. Sometimes it is necessary to make individual components or details. During the process there is intensive communication with the subcontractors.

5.Analysis of the main prototype:

A comprehensive analysis, discussion and review of the main prototype is carried out. Different technical characteristics are analysed: structure of the prototype; functional characteristics; styling characteristics; ergonomic zones; main analysis of components and details; analysis of used materials and production technologies for its manufacture; principles of assembly and disassembly, if available in the prototype, etc. If the characteristics of the main prototype allow it to be installed and used in real conditions and environments, a view, data collection and thorough analysis are performed. To perform such a process, its level of functionality is taken into account – a lack of such a function, partial or close to the real functionality of the product.

Important:

Developing a strategy for modeling and prototyping, according to the priorities of the project, product type and its purpose – mockups, product models, experimental models and functional prototypes. It is impossible to determine accurately the amount of models and prototypes to be produced before the start of Stage: “Models and Prototypes”. An indefinite number of models and prototypes is produced in the process of the stage, tailored to the specific end result, that has to be achieved. The production cost of the stage, departmental models and prototypes, as well as each detail, is impossible to determine until the previous two stages have been completed: Stage: “Conceptual Development” and Stage: “3D Modeling”. Information on the value of individual products that build models and prototypes could be obtained from subcontractors only if there are 3D files. It is only then possible to receive specific price offers from subcontractors. The communication process is very important and it specifies: a final selection of manufacturing technologies and materials for the production of models and prototypes; the production cost of components and details; determining the total production cost of the stage; optimization of the details, taking in to account the technological requirements for their manufacture, etc. During the communication with subcontractors, it may be necessary to upgrade and correct 3D models – 3D files. This is done in order to meet the production requirements of the specific manufacturing technologies and materials used by the subcontractors.

Pre-Production prototype

1.Collaboration with specialists:

Intensive communication, consultation, preparation and collaboration with specialists, subcontractors and manufacturers in different fields is performed, while adapting the product of manufacturing. There is an intensive joint activity with manufacturing, sales and marketing departments of companies, subcontractors and specialists in the respective fields. Feedback is obtained from a wide range of profiled specialists, independently whether they are engineers, design engineers, technologists, marketers, economists, managers, academics, hardware and software specialists, subcontractors, manufacturers and others. It is necessary to communicate, consult and collaborate with external companies and specialists, different from the client’s team or company.

2.Manufacturing technologies and materials:

Selection of production technologies and materials. Analysis and discussion of different types of materials and their characteristics – purpose, mechanical properties, usage of the product, etc. After selecting the type of material, selection of manufacturing technologies is made. The production requirements of the respective technology are discussed and analysed – adaptation of the product  to the engineering and technological requirements of the manufacturers and the types of machines, materials, processes, etc., used by them. Additional modification and product preparation towards the requirements regarding the type of mold tooling, quantity of production (manufacture type), assembling of the product, etc. is performed.

3.Research and selection of manufacturers:

Research, inquiries and consulting with the aim of discussion and analysis of production requirements, bidding and determination of production cost of the product etc. Communication with manufacturers and discussion of the product: type of manufacture and specification of technological characteristics; selection of materials by specification; compliance with standards and requirements; discussion and development of mold tooling; optimization of production stages and finishing processes; production cost determination, etc. Receiving feedback from manufacturers and analyzing the production process of the product with the assistance of their departments – commercial, engineering and manufacturing. After the communication, main selection of manufacturers is made, which extends the joint activity and further develops the process of product adaptation into manufacturing.

4.Development of pre-production prototype:

Development of a pre-production prototype, in the form of a single production, to come as close as possible to the technical characteristics and parameters of the final product – structure, function, materials, styling and others. The pre-production prototype differs from the main prototype, from Stage: “Models and Prototypes”. In the main prototype, the identity to the real product can reach 50%, where in the pre-production prototype the critical and unacceptable limits are 50%. The pre-production prototype should achieve an identity of not less than 80% – of the technical characteristics and parameters of the final product. Any compromises that are likely to be made and will not significantly and tangibly take away from the main product characteristics and parameters of the pre-production prototype are discussed and analyzed. Only then begins the process of development. Of course, the desired maximum result is always 100% identity compared to the final product. This is achievable, but further discussions take place on the set priorities, opportunities and objectives of the project. In the main prototype, compromises and experimentation with technologies, materials, structure, functions, etc. are allowed, while in the pre-production prototype, the technical parameters  of the real product – structure, functionality, ergonomic, styling, usage of the product and others, have to be maximum close. In the process of development of pre-production prototype, very often is necessary production of more than one product – from single to small-scale production of products, in order to justify the investment, expenses, the reached production cost and the complete preparation of the production process. In many instances, small-scale production of products is used for various purposes: providing customers with the product and using the product in real-life conditions; usage as an economic and marketing argument to investors; usage in campaigns еxample: crowdfunding – to raise capital, attract customers during the campaign, and potentially finding partners; for presentations in exhibitions as opportunities for potential markets, distributors and partners; for promotional campaigns and events that promote and present the product, etc. Such production is usually called a “zero series production” or a “test series production”. According to the specifics of the development and its production characteristics, it can vary in a large range – from 25 to 250 pieces of products. It is possible to reach larger quantities of products, but this depends on the set final goals and priorities in the project. In the process of pre-production prototype often is used mold tooling, as well as ready details, elements, accessories; they are adapted to the potential implementation, at the relevant small scale production, from which further processes occur – such as assembling. In most cases, the manufacturing of pre-production prototype is performed by several subcontractors. When having appropriate opportunity it is preferable to produce the product with potential manufacturers, with experience in small scale production and mass production. Manufacturers, who have technological capacity and resources for product implementation – zero series production, small scale production, medium series production or mass production, they also have the potential for production of models and prototypes.

5.Analysis of pre-production prototype:

Main analysis, discussion and review of the pre-production prototype – of basic structure, components, details and elements. Usage of the prototype in real environment and conditions –  based on that a detailed analysis of its functionality is carried out and what impact it has on its overall structure, components and details. Individual analysis of all the components, details and elements that build the pre-production prototype. All major areas of the structure are tested – they are put to intensive loads, which determine the characteristics of the materials and their physico-mechanical characteristics. This is an extremely intensive process that establishes the real characteristics and index of the pre-productuction prototype – functionality, usаge of the product, materials and others. The prototype is put on aggressive impact, it is assembled and disassembled to determine what would be the changes of its structure. Possible upgrades, modifications and corrections to the 3D models (files) are discussed, with the aim to optimize the product: design and change of structure; details and parts development; upgrade of functionality, usаge of the product and assembling; material changes, ergonomics and styling features – textures, colors, info zones, usage of the product and application, etc.

Important:

It is necessary to carry out a preliminary basic analysis and discussion before undertaking any further actions, related to the launch of Stage: “Adaptation of Manufacturing”. If the assignor of the project (team, company, etc.) has a commercial department, marketing department, engineering department, R&D department and manufacture – a process of communication, consultation, discussion and joint activities is held, with the respective specialists: engineers, design engineers, technologists, marketing specialists, economists, managers, software and hardware specialists, academics and others. If the assignor does not have a team and specialists for consultations and development of the product, such are being selected for the project. This has to be discussed in order to prepare the project to go through each of the stages of the project process – “Product Design & Development”. All of this is done immediately before the start of the first stage of the project process – Stage: “Conceptual Development”. After the completion of Stage: “Adaptation of Manufacturing”, the project enters the processes and stages outside the current project process stages of “Product Design & Development”. These are processes related to different stages for the further development of the product: manufacturing processes related to product implementation stages; processes for organizing the manufacturing and achieving production costs; management of economic processes and optimizing different types of costs; processes for quality control and compliance with standards; creating of marketing strategies, advertising campaigns and events for product presentation; offering and selling the product on the market; organization of distribution and logistics, etc.