DT: A2.2 (Prototypes) + A3.1 (Material Classification + Properties) + B2.2 (Modelling + Prototyping)

Dt flashcardz

What is a prototype?

An early representation of a product that allows designers to test, refine and validate their concepts before full production.

Why are prototypes developed? (inc purpose)

They are developed so that designers can explore different ideas, assess feasibility, and identify potential issues before committing to costly manufacturing costs.

What is a mockup?

A mockup is a quick sketch / basic representation of a product, demonstrating form and layout.

What is a physical model?

A physical model is a real life representation of a product, that allows designers to test ergonomics, mechanical functions, and structural integrity using real materials.

What is a virtual model?

A virtual model is a representation of a product using CAD, enabling designers to test and analyze designs without the need for physical production.

The positives and negatives of low, medium and high fidelity models

Low

• simple, quick, and inexpensive but also lacks detail, may not fully communicate functionality or aesthetics.

Medium

• balances speed and detail, provides a clearer representation of layout and interaction and is useful for usability testing - however also needs further testing and requirements .

High

• Closely resembles the final product, allows for detailed user testing and stakeholder approval. However is also time-consuming, expensive, and harder to make major changes.

2D physical models

A physical model can be made using card or polypropylene, and is usually drawn from a 2D side perspective.

2D virtual models

A 2D virtual model is usually drawn from a 2D side perspective using CAD. It can also be communicated in the form of an infographic.

1 point perspective

Has only one vanishing point on the horizon line, which usually shows the depth of roads, buildings or hallways.

2 point perspective

Have lines that converge between two vanishing points on the horizon line. The horizon is set at eye height.

3 point perspective

Adds a third point to the horizon line, which adds another sense of reality to the design. Used in product design.

Circles in perspective

Circles change shape in different perspectives and become an eclipse.

1st angle projection

When the views are drawn in their relative position. Top view comes below front view, and right side view is drawn to the left of the elevation.

3rd angle projection

When the views are drawn in their relative position. Top view comes above front view, and right side view is drawn to the right of the elevation.

Scaled drawings

Needed when an object is either too big or too small to draw in reality. Maps are examples of this.

Concept sketching

Concept sketching is a spontaneous representation of ideas on paper, without the use of technical aids. Used very early in the design process - fast, low fidelity expressions of initial ideas.

Formal drawings - orthographic, isometric, assembly drawings, exploded drawings, apart drawing

They are more developed versions of concept sketches. Orthographic, isometric projection, assembly and exploded views are examples.

Positives of concept modelling

Shares a general idea/‘big picture’, easier to understand, more communication between members, establishes proportion, gauges reactions to concepts and ideas.

Negatives of concept modelling

Lack of detail, can be misinterpreted, scale models are misleading, materials may be different to the final model, details can be left out.

Graphical, physical, virtual (prototypes)

Graphical - sketches, models, flow diagrams, Physical - clay, card, rapid prototypes Virtual - CAD.

Design thinking models

The design thinking model represents a collection of steps that a designer can follow to achieve a workable solution. Throughout the whole process there is an emphasis on communication of ideas. Designers will use conceptual modelling to express these ideas.

All of the different kinds of modelling materials

Balsa wood, styrofoam, card, cardboard, clay, paper, 3D printed plastic.

Scale models

A scale model is a smaller or larger physical copy of an object. Scale models allow the design ideas to be visualised, e.g. in architecture.

Functional models

A functional model is a prototype or representation of a product that demonstrates how it works. These models are used to test mechanics, usability, and interactions before final production.

Physical prototypes

Mechanical prototypes

electronic prototypes

engineering models

medical device prototypes

UI clickable prototypes.

Surface modelling

Surface models are photo-realistic images of a model, offering some machining data but no data about the interior of the product.

It gives a geometric mass to the product (exterior).

Data models

A data model defines the structure of data, including statistical models (e.g. databases, information systems, sports development and product design.)

Solid models

Solid models are detailed, accurate representations of the final product.

They contain all necessary data, including internal dimensions and structural details, allowing the product to be fully realized.

Motion capture

Motion capture is the recording of human and animal movement.

It is done in a variety of ways including video, magnetic, or electro-mechanical devices.

Haptic technology (all 4 examples)

Haptic technology is a technology that interfaces the user and a product via a sense of touch. It works by using mechanical actuators to apply forces initiated by the users movements.

Entertainment

Robots

Wearable Haptics

Touchscreens.

VR, digital humans, CAD animation

Virtual reality is the ability to simulate a real situation on a screen and interact with it in a near-natural way, computer generated.

Digital humans are computer simulations that replicate mechanical and biological aspects of the human body.

They interact with digital prototypes, allowing for faster product development by enabling multiple design iterations tailored to human specifications.

Animation is the ability to link graphic models and images together in such a way as to simulate motion or a process, simulating various design concepts and contexts.

Finite element analysis (FEA)

Finite element analysis (FEA) involves the calculation and simulation of unknown factors in products using CAD software.

For example, simulating stresses in a welded joint. FEA has become a solution to the task of predicting failure due to unknown stresses and heat transfer.

Stereolithography (SLA files)

Stereolithography creates models/prototypes from lasers that cure liquid plastic into solid objects, resulting in smooth surfaces.

FDM

Fused deposition modelling is the usual method of 3D printing, adding layers on top of one another. It starts with a CAD model that then produces a SDL file.

SLS

Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal, ceramic or glass powders into a desired 3D object.

They are commonly made out of plastic powders, such as nylon, which are automatically dispersed in a thin layer on top of the build platform.

They are very intricate and detailed, normally with holes in them.

Top down and bottom up modelling

Top-down starts with the big picture (strategy, overall goals) and breaks it down into details, while bottom-up begins with details (individual components, data) and builds them into a whole, common in project planning, software, and finance, with top-down offering speed and direction, and bottom-up providing richer detail and buy-in, often used together.

Hybrid modelling

A hybrid approach to modelling combines both top-down and bottom-up techniques.

Custom components are typically developed using top-down modelling, while off-the-shelf or standardized parts are incorporated through bottom-up assembly.

SDL file

CAD files must be Standard tessellation language (STL) is a file type that translates files into a different ‘language’ or a file type that 3D printers can understand.

CAD models must be broken up into layers before being printed in three dimensions and STL files ‘cut up’ CAD models into layers, giving the 3D printing machine the information it needs to print each individual layer.

Explain the power of drawings in communication - 4 main points

They can:

Visualise ideas

Communicate complex information

Facilitate collaboration

Problem-solving

2D drawings - examples and significance

2D drawings provide clear and precise representations of objects or spaces on a flat plane

Examples:

Schematic diagrams (electronics)

Maps

Architectural floor plans

Blueprints

Technical drawings (engineering)

3D drawings, understanding and examples, identify the key differences

3D drawings have 3 dimensions, which allow for a more realistic and comprehensive visualization.

They have depth and perspective and a variety of forms.

They are different from 2D drawings because of their depth, realistic visualisation, complexity and conveying the overall form of an object

Examples of 3d drawings:

3D modelling (CAD)

Architectural renderings

3D animation CGI

Medical Imaging

3D printing

Low fidelity prototypes are:

Quick, easy and inexpensive for early stage development (and visualisation)

Use simple materials like cardboard, foam and paper

Medium fidelity prototypes are:

A more refined representation of the product (aesthetics and functionality)

May incorporate functional components (E.g. a 3D printed model)

High fidelity prototypes:

Closely resemble the final product

Often used for final testing, and validation before mass production (E.g. a fully functional prototype of an electronic device with a finished enclosure)

FEA recap

Finite element analysis (FEA) involves the calculation and simulation of unknown factors in products using CAD software.

For example, simulating stresses in a welded joint. FEA has become a solution to the task of predicting failure due to unknown stresses and heat transfer.

Importance of FEA:

Reduces Physical Prototyping

Optimises Product Performance

Enhances Safety and Reliability

Supports Sustainable Design

Applications of FEA in Design:

Automotive Aerospace Medical Devices Consumer Products

Numerical data / Numerical File Formats:

STL, OBJ, or STEP are used to export CAD models for 3D printing or CNC machines, ensuring compatibility with prototyping equipment

What is plasticity?

Plasticity is a material’s ability to be permanently deformed, meaning it can be bent, shaped, or stretched without cracking or breaking, and it doesn’t return to its original shape afterwards.

What are physical properties of materials?

Physical properties include:

Density (how heavy a material is for its size)

melting/boiling point (temperature at which it changes state)

thermal conductivity (how well it conducts heat)

electrical conductivity (whether it conducts electricity)

and transparency or opacity (how light passes through the material).

Why are materials classified?

Materials are classified based on physical, chemical, and mechanical properties to help designers:

select the right material for a product's function and environment

allow easy comparison between materials

help predict performance and durability

ensure safety

cost-effectiveness

and regulatory compliance

support clear communication between designers, engineers, and manufacturers.

What is elasticity?

Elasticity is the ability of a material to return to its original state after being stretched or compressed.

What defines chemical properties of materials?

Chemical properties define how materials change permanently, causing chemical transformations that may release toxic substances or determine corrosion resistance against chemical reactions, such as with moisture or oxygen.

What are smart materials?

Smart materials are materials that have properties that can be controlled in response to external stimuli, such as:

photochromism (change of color when exposed to light)

thermoelectricity (conversion of heat into electrical energy)

magneto-rheostatic/electro-rheostatic (fluids that change viscosity under magnetic or electric fields).

What should designers consider when choosing a material?

Designers need to research, test, and compare the functional, aesthetic, environmental, and economic requirements of the product, as well as explore new materials and technologies for a better fit.

What is brittleness?

Brittleness is a property of a material that makes it prone to break or fracture easily under stress.

What does it mean for a metal to be ductile?

A material is ductile if it can be drawn into a wire by stretching, indicating its ability to deform without breaking.

What are composite materials?

Composite materials are made from two or more bonded materials to improve their mechanical or physical properties, such as glass in sheets, Kevlar, or Carbon Fibre, which consist of a reinforcement (fibre) and a matrix (resin/plastic).