Using Physical Models in Design
Using Physical Models in Design
Alex F. Lennings
Delft Spline Systems, The Netherlands
Abstract Introduction
In the conceptual phase of designing consumer durables, A design process is a multi focal and complex process.
important decisions are made for the investment and the The designer with his abilities and experience plays an
extent of downstream efforts and activities. These important active role in that process. For his purpose he
decisions are important for the overall costs of a product can rely on methodologies, supporting tools, company
and finally for the success of the product. Although, procedures and culture, and accessible information in
virtual concept modeling is available, the application of any form. The design process will depend on the fact
physical models can be justified by the fact that these whether the design task is to redesign a product, or to
models supply a base for communication, support and extend a family of products or to develop a completely
improvement of the creativity of a designer. newly product. The complexity of the design process is
In current rapid prototyping, the focus is on physical influenced by the complexity in function and structure,
proof-of-concept models and going towards rapid and is demonstrated by the enormous amount of related
fabrication. Physical models in the conceptual design papers. A substantial part of the papers are focussed on
stage are, due to the nature of conceptualization, the development of supporting tools. Subjects like what,
different from those models, which are applied during how and when to support the activities of the designer
the detailing stage of design. Some reasons for this are are discussed. Due to the individual abilities, flavor and
vagueness and incompleteness of product models, and qualities, diversification, functionality and complexity
different model usage and design. In this paper an of products it is impossible to create one single solution
inquiry among Dutch designers explores that statement. or method for design tasks.
The first part of the inquiry showed that physical In this paper the authors will explore the optimal usage
models in the conceptual stage of design are different of physical models in conceptual and detailing design.
from those applied in the detailing stage of design. All Physical models, produced by rapid prototyping
designers recognized that. The second part of the technology, to support detailing design are commonly
inquiry explores in what way they are different. accepted and applied. It is also recognizable that
Our study brings forward that a better understanding has physical models, which are realized by rapid
to be achieved in terms of using physical concept prototyping in a conceptual design stage, are very
models supporting conceptual design. Various scarce and almost nonexistent. Reasons are the vague
applications for conceptual models are possible such as geometry and the nature of the conceptual design stage.
shape verification, communication, presentation, and In design, models are produced to answer specific
functional testing. Each model will be tailored optimal designers' questions [1]. When the conceptual model
for that usage and categories of models are recognized. provides the answer to that question and the analysis is
New dedicated prototyping technologies are needed to completed the model is wasted and the remaining value
acquire the best performance. The process needs support is maybe a capture of a part of the design process or the
from a combination of tools, like natural geometry procedure. In order to minimize the effort of fabrication,
input, useful vague geometry representations, in general a model must be created to meet as close as
representation translators towards accepted CAD possible the necessary requirements. The conceptual
formats. When these facilities are available the input for model must be tailored for that purpose.
rapid prototyping is possible. In the conceptual design stage the sequence of ideas,
However, for a feasible implementation there are also thoughts, possibilities and challenges can change
requirements for the rapid prototyping process in terms rapidly in time. Moreover the problem solving process
of turn-around time, cost, process innovation and can be characterized as being aspect oriented.
flexibility. The conditions for a feasible rapid It is in these circumstances very useful to produce
prototyping process are discussed. physical models within a short period of time to assure a
supporting contribution into the design process. Current ? design bureaus working with 3D CAD and 3D
rapid prototyping technologies will take in case of product design.
outsourcing one or more days, which time frame is ? activity of the design bureaus into: product and
acceptable for pre-production prototypes. But it will industrial design, product and concept
prevent the usage of these tools during the conceptual development, production, ergonomics and
design phase. consultancy.
Together with the time-compression in all design ? size of the bureaus
activities, concept design requires model fabrication From the about 39 design offices, which could be
facilities in house and models must be available within selected and contacted finally 50% of the offices (20
one or two hours. [2] forms) responded with a completed form. The presented
In the conceptual design stage, far-reaching decisions results are based on these responses.
are made about the final product and product From the responses about the number of employee’s is
realization. It should be advisable to have supporting noticeable that design bureau’s of 1-6 persons represent
tools like easy to produce physical models for reasoning about 55% of the responses and another 35% have 6-20
and verification of the design actions. But at the same
time, the acceptance of these facilities by the designer is Number of Design Related Employees
important for a sound implementation of rapid
60
prototyping technology in a conceptual stage of design.
The problem of applying physical models in conceptual
Response in %
design is hampered by the complexity of the character 40
of aspect development.
The goal of this paper is to establish the fact that 20
h
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number of employee’s
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? activity domain
Fig. 2 Design bureau activities
? design tool application
? number of prototypes for product design active in various other activities. Production preparation
In the next paragraph a discussion about results of and ergonomic design activities are scoring low. The
model characteristics are presented. response “Other” fields is related to activities like
A selection from available design offices in the product identity, brand development, and product
Netherlands 39 product design bureaus were selected styling.
and contacted. The selection criteria are:
The response on the application of design tools (Fig. 3) In Figure 5 the amount of physical models produced
illustrates that implementation of virtual and physical during a product design is presented. Noticeable is that
Application of Design Tools Typical Number of Prototypes During
Product Design
100
50
Response in %
75
Response in %
50
25
25
0 0
1-2 3-5 6-10
RP
M
s
r
pe
oft
d
he
re
ca
ca
PC
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ha
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Number of prototypes
Ot
2D
3D
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Vi
Fig. 3 Implementation of design tools Fig. 5 Amount of models in product design
based tools (a distinction is made in: handmade shape 80% of the cases don’t produce more than 4 to 5
and presentation models and models produced via rapid models. However, 20% needs more than 5 models. It
prototyping) are equally applied and implemented in should be investigated whether the distinction [1] of
product modeling. The response “Other” is related to specification and prototype driven company cultures are
sketching (not explicitly mentioned in the inquiry). debit to that.
Remarkable is the score of Physical Concept Modeling The designer himself does not frequently produce
(PCM) [3] which is scarcely applied in product physical models (due to lack of facilities, time, cost, and
development, although rapid prototyping is fully effort). Model making is expensive and the useful effect
accepted as a tool. It can mean two things that there is is often not straight forward visible. So, the effect of
no need for PCM or maybe there is no notion and such an investment is questionable. And, in turn, the
known application example for PCM. Further it is application of physical models in product development
noticeable that visualization software is a very general is influenced.
applied tool. Next the response on the question: “Do you agree that
Figure 4 demonstrates that digital modeling and physical models in conceptual and detailing product
verification for a major part is done in house. Physical design are different?” is presented. Almost all designers
recognize very clearly the model difference between
Design Tool Application in House models, used in a conceptual design stage and those
used in a detailing stage of design. Now the designers
100%
approve this assumption about physical model
differences in either product design stage, it is time to
Response in %
75%
no resp
never
consider the following. When they differ, in what way
50%
occas or extent they will differ. The next we will focus on
always that. First prototypes for design support and then the
25%
properties and characteristics of the prototypes are
0% considered, in the next paragraph.
RP
r
pe
s
ft
d
he
So
re
ca
ca
PC
ha
Ot
Vis
2D
3D
Hs
75%
is not yet accomplished this paper. The classification no resp
Both
can supply information for geometric preparation 50%
Detail
process as an input for rapid prototyping processes. Conc
Today, materialized models are mostly generated from 25%
rif
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pr
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n
us
nc
he
processes are based on an incremental layer method and
Dis
go
Ve
Re
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M
Fu
Ot
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Co
are highly or completely automated. The principle is the
subdivision of CAD data in easy to manufacture parts Fig. 6 Usage of prototypes
(very thin slices). The shape is built by deposition of In Figure 6 physical models are mostly used for the
layers, each layer is manufactured separately and the purpose of representation, discussion and ergonomic
layers are stacked onto each other to create finally a evaluation. There is also much usage in the detailing
physical model. Different incremental technologies exist stage of design for geometry verification and functional
on the RP-market, e.g., 3D printing, stereolithography,
layered object manufacturing (LOM), selective laser
testing. Functional models are used in either design
Importance of Physical Models and Rapid
stage. Prototyping
20
75% no resp
Response in %
very high
15 high
50%
Frequency
normal
low
10 very low
25%
5
0%
Creat Verif Creat Verif
0 Physical Models | Rapid Prototyping
r
ul
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od
rt
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Tim
fo
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Dm
an
Sti
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Fig. 9 Importance of physical modeling
no
ch
D
CA
CA
ct
no
pe
no
As
shown that physical models in creativity and
Fig. 7 Where to apply handmade models verification and rapid prototyping in verification are
The response (Figure 7) indicates that handmade models equally appreciated.
are mainly used to stimulate and to support designing
activities and creativity. It seems that items mentioned Aims of Rapid Prototyping
in the inquiry did not sufficiently match, because the 20
response “Other” is the second in the response score.
The issues mentioned there are: testing of mechanical 15
Frequency
Both
principals, idea verification, principle learning and 10 Detail
understanding, large sized models, communication, and Concept
in a wider aspect to sense the physical properties (form, 5
material, weight).
0
Role of Model Type Conceptual and
n
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pic
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Detailed Design
Dis
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om
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100%
Response in %
il
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eta
De
De
nc
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RP
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RP
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30
response in %
30
response in %
Process
Visual Concept 20 Concept
20
Process
Visual Detail
Detail
10
10
0
0
Co lor
Tr t
sp
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er
ler c
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Fe ual
rd l
M es
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W s
Su acc
ap pea
Str sgn
Ha teria
ap n
To ac
s
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Material
Tolerance
Oth
eig
Surf qual
Color
Shape acc
o
Weight
Transp
Hardness
Conduct
Appear
Shape, dsgn
Sh Stiff
Features
Geom acc
an
ne
r
nd
Str., Stiffn
rf q
C
atu
Other
e
Sh Ap
a
.,
Fig. 14 Process model characteristics
Fig. 11 Visual model characteristics shape and design is scoring high, although in concept
design this characteristic is 1.5 times more important.
For detailing the characteristics like strength and
Communication model characteristics stiffness, tolerance, and geometric accuracy are scoring
40 better than in concept design. Concept design scores
better in the application of features and color.
30 In Figure 13 the characteristics of the functional models
response in %
ht
er
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ua
eig
pe
Oth
tiff
an
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rf q
., S
Ap
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To
Function
and transparency.
20 Concept
Function
Detail Discussion
10
In conceptual design the product is under development
0 results in vague, incomplete, fragmented, and temporary
information. Often no digital representation of the
e, ar
nd r
er
Tr t
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