Hybrid Prototyping: Pure Theory or a Practical Solution to Accelerating Prototyping Tasks?

Abstract

Physical prototyping is critical activity in the produce development process, but the cost and time required to produce prototypes hinders it use in the design process. Hybrid prototyping through coupling LEGO and FDM printing is presented as an approach to address these issues. After establishing the separate design rules for FDM printing and LEGO, this paper created new set of rules called Design for Fabrication (DfF) for hybrid prototyping. These cover the three main considerations (Technical, Process, and Design) that the designer and process planning must include to practically implement LEGO and FDM hybrid prototyping. The DfF rules were considered in a prototype of a computer mouse. While the fabrication time was not reduced as expected, it showed that the rules could be practically implemented in a real-world example. Additional considerations were identified that are to be included in the DfF rules.Further work is required to realise the predicted step-change reduction in fabrication time. The first approach is to leverage multiple printers to parallelise the printing. The second is to reduce fidelity while maintaining high fidelity in key regions of interest.

Perception-centric design considerations for low-cost haptic emulation in prototypes

“…Therefore, a compromise exists between prototype realism and minimising expenditure, either through reconfigurability or perception-centric design. Reconfigurable models could replace dozens of physical prototypes, and open up the possibility for end-users to collaboratively navigate the design space with designers, facilitating richer feedback (Mathias et al, 2019). Perception-centric design aims to maximise user engagement, realism, and economisation by understanding where best to focus efforts; either reducing the fidelity of non-contact/low-impact elements or increasing the fidelity of high-impact elements (Cox et al, 2022).…”

A comparative study of VR CAD modelling tools for design

“…As CAD tools lack immersion and intuitiveness, they struggle to give a real-life feel of observing and creating parts, which ultimately obstructs the intent of the user (Nanjappan et al, 2023). Contrary to modelling using software, creating something with clay or Lego gives creative freedom, ease of use, and efficiency due to its intuitiveness and existence in 3D space (Mathias et al, 2019). A similar sculpting-like tool may help design as intended by simply removing material from the desired places instead of designing through hierarchical steps as in CAD.…”

How Do Prototypes Change? Characterising Quantitative and Qualitative Changes Between Prototype Iterations

“…For example, (Real et al, 2022) investigates remanufacture as a method to cut time between prototype iterations, showing a significant potential reduction in fabrication time of up to 87%. Mathias et al (2019), couples Additive Manufacture (AM) with LEGO in a hybrid process, reducing fabrication time by 45%. Whilst these works show promising results and give indication as to the direction in which prototyping strategies are tending, it is apparent that little is known about the characteristics of changes that such strategies are intended to affect.…”