Realities of Virtual PrototypingJonathan Prince

What are we talking about?

• What is virtual prototyping from an engineering perspective?

• Why perform virtual prototyping?• Time to market• Accuracy of design• Risk mitigation

• Real life examples of the difference virtual prototyping can make…

What is virtual prototyping?

• Understanding the build process• Simulating Loads and working conditions• Simulating fatigue- long term loads• Simulating the component manufacture• Understanding the manufacturing/ assembly

process

Virtual prototyping?Nah, I’ll just whip one up!

• Stress Analysis• Understand loads / forces early• Remove unnecessary weight / material

• Flow Analysis• Will the mould fill?• Will the part last?

• CAM – Machining• Can the mould/ part be made?!

• Rapid Prototyping• Visualisation• Check fits

Embrace Technology

Why is virtual prototyping important?

• Time to market• Crucial to product profitability

• Accuracy of design• Crucial to the brand, the product and success of the

company

• Mitigating risk

Why is virtual prototyping important?

Time to market

Late to Market

Lost revenue

1 2 3 4 5

Volumes/ Sales

Time

Time to market

Time to market

• “Products that come to market six months late but on budget will earn 33% less profit over five years…

• In contrast, coming out on time and 50% over budget cuts profits by only 4%”.

• - McKinsey and Company

Why is virtual prototyping important?Mitigating risk

www.latimes.com

Risk: The probability of something happening multiplied by the

resulting cost ($$ or life) if it does.

Risky? Really?!

Case study: Life changing!

Why is virtual prototyping important?Accuracy of design

Fit for Purpose?

• Can it take the loads?• What are the loads?

• Can it handle the environmental conditions?• What are the long term, ongoing scenarios?

• How might this be used & abused?

• Rubbish in = rubbish2 out

Case study: How hard can it be?

• Feller/De-limber• $150k per unit• Failing in the field • Analysed for failure

• And then we checked it in the field!

Case study: Lucky?!

• $1/4M prototype• 25 Year life • 10 Million cycles• 3 month test cycle

Analysis process

• Progressive

Analysis process

• Progressive• Conservative

railpictures.net image © phil cotterill

Analysis process

• Progressive• Conservative• Controlled

Analysis process

• Progressive• Conservative• Controlled• Validated

Case study: Lucky?!

• $1/4M prototype• 25 Year life • 10 Million cycles• 3 month test cycle

• Right first time!

Get it right, before you cut steel!

Design without analysis is like pilots without instruments; they

know they’re flying, but they might not know exactly where

they are!

Over the Top?

Summary

• Build virtual prototyping into your development process

• Don’t skimp on the engineering

• Rubbish in = rubbish2 out

• Develop a virtual prototyping methodology

• Get it right before you cut steel