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How do you create prototypes with software and tools?

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Prototyping is an essential part of manufacturing engineering, as it allows you to test and refine your design ideas before investing in mass production. However, creating physical prototypes can be costly, time-consuming, and wasteful. That's why many manufacturing engineers use software and tools to create digital or virtual prototypes that simulate the performance, functionality, and appearance of the final product. In this article, you'll learn how to create prototypes with software and tools, and what benefits they offer for your manufacturing engineering projects.

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Karthikkraja Gopalakrishnan

Leading Loyal Wingman Technologies with Strategic Vision and Innovation

1 Choose the right software

Depending on your project goals, budget, and preferences, you can choose from a variety of software options to create prototypes. Some of the most common ones are CAD (computer-aided design), CAM (computer-aided manufacturing), CAE (computer-aided engineering), and VR (virtual reality). CAD software allows you to create 2D or 3D models of your product, CAM software helps you generate toolpaths and instructions for machines, CAE software enables you to analyze and optimize your design for various criteria, and VR software lets you immerse yourself in a realistic simulation of your product.

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Karthikkraja Gopalakrishnan

Leading Loyal Wingman Technologies with Strategic Vision and Innovation
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One of my insight is stick to the customer based software and tools. Lookout for Version Issue and Revision whether that is compatible with them. It is a quick and easy way of identifying the right software. Another method is universally acknowledged software tools which is used in many industries of your targetting nature.

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2 Define your prototype scope and requirements

Before you start creating your prototype, you need to define its scope and requirements. This means deciding what aspects of your product you want to prototype, what level of detail and fidelity you need, what feedback and data you want to collect, and what resources and constraints you have. For example, you may want to prototype only a specific feature or component of your product, or you may want to prototype the whole product. You may also want to create a low-fidelity prototype that shows the basic concept and functionality, or a high-fidelity prototype that mimics the final appearance and performance.

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Karthikkraja Gopalakrishnan

Leading Loyal Wingman Technologies with Strategic Vision and Innovation
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If you are planning for a prototype and it is of high value a high fidelity prototype always show you the truth... Some Cases this may change and a low fidelity protype is enough but it depends of its end use case. Defining the scope by sitting along with your customer is key here to decide which prototype is enough. Also designing for manufacturing requires production and planning input as a must.

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3 Design your prototype with software

Once you have your software and your scope and requirements, you can start designing your prototype with software. Depending on the software you use, you may have different steps and methods to create your prototype. For example, if you use CAD software, you may have to sketch, model, extrude, fillet, chamfer, and assemble your product. If you use CAE software, you may have to apply loads, boundary conditions, materials, and mesh your product. If you use VR software, you may have to import your 3D model, add textures, lighting, and sounds, and configure your interactions.

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4 Test and evaluate your prototype with software

After designing your prototype with software, you need to test and evaluate it with software. This means using the software features and tools to simulate how your product would behave and perform in real-world scenarios. For example, if you use CAM software, you can run a simulation of your machining process and check for errors, collisions, and efficiency. If you use CAE software, you can run a simulation of your stress, strain, deformation, vibration, heat transfer, fluid flow, or other physical phenomena. If you use VR software, you can wear a headset and controllers and experience your product in a virtual environment.

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5 Iterate and improve your prototype with software

Based on the results of your testing and evaluation, you can iterate and improve your prototype with software. This means making changes and modifications to your design, parameters, or settings, and repeating the testing and evaluation process until you are satisfied with your prototype. For example, you may want to change the shape, size, or position of your product features, or the material, load, or boundary conditions of your analysis, or the texture, lighting, or sound of your simulation.

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Karthikkraja Gopalakrishnan

Leading Loyal Wingman Technologies with Strategic Vision and Innovation
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Iteration and improvement is the basics of any Design process and cost effective method is doing it through visualisation and simulation.... Most design softwares offer this simulation which saves significant cost incurred if it is trialled using raw material directly before freezing the design.... Config control is key here otherwise all the iterations done would end in vain so use the PLM software for wase of doing design iterations and improvements

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6 Export or print your prototype with software

Finally, if you want to create a physical prototype from your software prototype, you can export or print it with software. This means using the software functions and tools to generate a file format or a code that can be used by a printer, a cutter, a mill, or another machine to produce your prototype. For example, you can export your CAD model as a STL (stereolithography) file and use it to print your prototype with a 3D printer. Or you can export your CAM toolpaths as a G-code and use it to cut your prototype with a CNC (computer numerical control) machine.

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Karthikkraja Gopalakrishnan

Leading Loyal Wingman Technologies with Strategic Vision and Innovation
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If it is of customised prototype and very high raw material cost go for 3D printing but if it is a bulk order you always find extra raw material in the allocated raw material contribution to do the First Article product so go for CNC operation to prove First Article...

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you create prototypes with software and tools?

1

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3

4

5

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1 Choose the right software

2 Define your prototype scope and requirements

3 Design your prototype with software

4 Test and evaluate your prototype with software

5 Iterate and improve your prototype with software

6 Export or print your prototype with software

7 Here’s what else to consider

Manufacturing Engineering

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How do you create prototypes with software and tools?

1

2

3

4

5

6

7

1 Choose the right software

2 Define your prototype scope and requirements

3 Design your prototype with software

4 Test and evaluate your prototype with software

5 Iterate and improve your prototype with software

6 Export or print your prototype with software

7 Here’s what else to consider

Manufacturing Engineering

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