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Functional testing with rapid prototypes is confined to certain areas due to a number of issues: the lack of a reliable similarity method that can solve distorted similarity problems; limited material choices; range of prototype sizes; and distinct material structures between prototypes and actual products. Methods are thus needed to expand the application of functional testing with rapid prototypes, and thus potentially impact the performance and cycle times of current product development processes. In this context, an improved similarity method that utilizes a geometrically simple specimen pair is developed in this paper. A realistic numerical simulation and an experimental mold design example (using a selective laser sintering prototype) demonstrate the validity and impact of the new method.

Discusses experiences on the development and use of horizontal and vertical prototypes. Explains the difference. Resolves that horizontal prototypes can be developed with ′little effort′, but end users are reluctant to become involved in the development process. Contrastingly resolves that vertical prototypes appear to stimulate constructive response. Reasons that developers should be aware of the tacit knowledge which plays an important part in users′ work practices and should be involved early in the development process. Proposes three techniques to meet the requirements – participation, simulation and evaluation.

To illustrate the benefits of using the empirical similitude method when creating scale models with rapid prototyping processes, particularly in the context of evolutionary product design.

Apply the empirical similitude method in two experimental examples. Utilize rapid prototyping processes to create scale models. Both examples are based on the context of evolutionary product design. For one example, evaluate accuracy of empirical similitude results as compared to traditional similitude.

The first experimental example showed improved accuracy in the empirical similitude results as compared with traditional similitude. The second experimental example illustrated an effective approach for applying the empirical similitude method to a realistic product evolution.

Limited to two experimental examples. Examples involve a single prototyping process (selective laser sintering). Does not cover limitations of the empirical similitude method.

The approach provides for an effective way of utilizing rapid prototypes to predict the functional behavior of an evolutionary product. Rapid prototypes are readily available, but are rarely used in evaluating product function, due to limitations in part sizes and material properties.

This paper provides a practical way of utilizing rapid prototypes to predict the functional behavior of a product through scale models. It also illustrates the proposed method with two experimental examples.

To provide an innovative way for manufacturing in which the integration of rapid technologies is simultaneously used methodologically in real‐time for the rapid product and process development (RPPD).

A range of related works are discussed and an experimental implementation of the RPPD methodology is described for composite functional prototype design and rapid manufacturing (RM). The simultaneous integration of VP/RP/RT/RE/RM technologies consolidates a powerful methodology to achieve the RPPD objectives.

The RPPD developed methodology takes advantage of both virtual prototyping (VP) and physical prototypes made by rapid prototyping (RP) technology to evaluate performances and design ergonomic aspects. The increasing needs to reduce lead‐time and costs have direct converting RP in rapid tooling (RT) technology for RM. Furthermore, to verify the parts and tools geometry accuracy the simultaneous use of scanning techniques for metrology control aided by reverse engineering (RE) as allow decreasing the RPPD time.

This paper evaluated RPPD results and the metrology control plotted in error distribution function and cumulative error distribution histograms validate the best practice developed that industrial manufacturers could implement allowing time and costs reductions.

This paper aims to argue about the involvement of additive technologies (ATs) in the prototyping issues of designing. More precisely, it reviews the literature contributions focused on the different perspectives of prototyping activities for design purposes, searching for both available knowledge and research needs concerning the correct exploitation of ATs.

A two-step literature review has been performed. In the first step, general information has been retrieved about prototyping issues related to design. In the second step, the literature searches were focused on retrieving more detailed information about ATs, concerning each of the main issues identified in the previous step. Extracted information has been analyzed and discussed for understanding the actual coverage of the arguments and for identifying possible research needs.

Four generally valid prototyping issues have been identified in the first step of the literature review. For each of them, available information and current lacks have been identified and discussed about the involvement of AT, allowing to extract six different research hints for future works.

This is the first literature review concerning AT-focused contributions that cover the complex and inter-disciplinary issues characterizing prototyping activities in design contexts.

To propose a method to manufacture a hybrid rapid tool (a multi component tool).

The part is decomposed into multi component prototype instead of a part made from a single piece. First, this method is based on a topological analysis of the tool. Features are regrouped starting from the numerical definition of the die. Second, the manufacturing possibilities of the high speed milling (HSM), direct metal laser sintering (DMLS) and electro discharge machining (EDM) process are analyzed. Finally this information is synthesized to obtain solutions. This method is validated by industrial example.

A method is proposed to choose the best manufacturing process in order to optimize the manufacture of a “hybrid rapid tooling” between three processes: HSM, DMLS and EDM. So, it is possible to obtain the different components of the hybrid rapid tooling according to the envisaged process.

The final goal is to propose a software assistant used in association with CAD system during the design of hybrid rapid tooling. An important work concerning the features recognition must be implemented. The assembly of the different parts of the hybrid rapid tooling must be considered and optimized.

This method allows the selection of the best process among EDM, HSM and DMLS technologies form manufacturing tools.

The analysis of manufacturing hybrid rapid tooling has not been studied yet.

Rapid prototyping can potentially accelerate the entire process of new product development (NPD), enabling a high level of customer involvement and hence new product success (NPS). This study aims to examine the relationship between prototyping and NPS, and the moderating effect of customer involvement, as well as the influence of speed of information dissemination on customer involvement.

Data were collected using the survey method through structured questionnaires. The key participants were management and team leaders from technology-based companies.

The results indicate that prototyping positively correlates with NPS, particularly when customer involvement is high. The speed of information dissemination, both from customers and on competitive products, has a positive impact on customer involvement.

The study was limited by the undefined development stage of the prototype when offered for customer feedback. Future studies could focus on how customer involvement at each stage of prototype development affects NPS through a moderating effect.

The study confirms that investing in prototyping equipment for NPD increases the probability of NPS. Information capturing customers’ views and on competitive products in the market should be shared among the NPD teams. This could encourage better sharing of opinions and perceptions with customers about whether new products meet their wishes and expectations.

This study demonstrates that customer involvement moderates the relationship between prototyping and NPS. The degree of customer involvement depended on the speed of response of the customers themselves and on how well competitive product information was disseminated within the NPD team.

The purpose of this paper is to investigate the adoption of rapid prototyping (RP) technology using three dimensional (3D) printer for infusing agility in traditional manufacturing environment.

The computer aided design (CAD) model of a knob of an electronics switch is developed using Pro/E software. Keeping this model as a reference, CAD models of new six knobs are developed. A 3D printer is used to build the prototypes of five of those CAD models. The receptivity of the practitioners over adopting CAD models and 3D printer for achieving agility is investigated.

The sensitisation of the industry captains and employees of traditional manufacturing sector is the imperative for exploiting the power of 3D printer and achieving mass customisation.

The paper reports an original research in which the practicality of using 3D printer is investigated with the objective of enabling the traditional manufacturing companies to imbibe agile characteristics.

In recent years, rapid prototyping (RP) and rapid tooling (RT) technologies have been implemented in many aspects of industry, especially in the area of new product development. Based on RP and RT technologies, the paper proposes a rapid design and manufacturing system of the product. There are two ways to develop a new product in this system. One is beginning with a design concept, and another is from a sample as a reference. The reverse engineering technology, transmission processing software or modules of the input data, structure analysis and optimization means and manufacturing process analysis tools were integrated in the system. Some examples show that the integrated system not only can reduce the number of design iterations but also improve the efficiency and reliability of the product design.

A seminar organised by the Rapid Prototype and Manufacturing Association (RPMA) held at the UK Castings Development Centre in Birmingham presented a series of case studies on the application of rapid prototyping methods in the manufacture casting tools. Methods described included stereolithography, laser sintering and sand cast moulding. Amongst the case studies were descriptions of the production of a novel A‐post for the Volvo Safety Concept car, the production and ranking for accuracy and repeatability of aerospace components and the direct production of sand moulds for cylinder heads and a hydraulic valve.