Prototype in New York. Hutch Hutchison, In T Hutch Ltd Inthutch@gmail.com

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1 Prototype in New York Hutch Hutchison, In T Hutch Ltd Inthutch@gmail.com

2 Prototype: (Webster) 1. an original model on which something is patterned. 2. an individual that exhibits the essential features of a later type 3. a standard or typical example 4. A first full-scale and (usually) functional form of a new type or design of a construction.

3 Several Types of Prototypes, depending on stage of development Proof of concept demonstrates the main functionality of the idea. off the shelf components unlikely to look like the final product. Visual prototype conveys the overall shape and size prove the function of the idea. Not final materials or production methods Presentation prototype. combines functionality with overall appearance. using bespoke/and or production grade parts and materials Pre-Production prototype. mass production manufacturing methods, materials, and parts

4 Prototypes are integral part of Product Development Process Idea/Need Production Design Pre-production Pre-Production Prototype Proof of Concept Prototype Stimulate Investor/SBIR Test Production Design Iterate Final Design Check Presentation Prototype Iterate Visual Prototype Visual Form/Fit/Functi on Test Final Design

5 Prototype in general 1. Determine the disciplines you need to build your prototype Mechanical, optical, electronic, software 2. Determine resources you have available in the company in those disciplines 3. Investigate resource availability through board members, other partnerships. 4. If you can t do 1-3, get help: TDO, FuzeHub, SU

6 1. Mechanical Most Common Prototype First of all, decide: Is the idea mostly mechanical or does it require mechanical support or housing? Mostly Mechanical: Proof of Concept can be sketch or drawing If appearance is crucial, CAD Model can suffice. Can prototype be constructed from off the shelf parts? If for investor, his attention is on the inventor,and idea less the appearance Mechanical Support or Housing: May not be necessary in early (Proof of Concept) prototype demo/breadboard of concept.

7 Rapid Prototype -Mechanical Rapid Prototyping (3-D Printing) has made significant progress recently. Prototypes can be made overnight in many cases. 3-d Printer: Same as your inkjet, but one layer at a time, makes solid model. Host of materials available: from bio thru exotic metals 4 methods of 3-D Printing: Stereo lithography: Photosensitive polymers printed with UV Fused Deposition Modeling: Layers of extruded plastics Selective laser sintering: Layers of plastic/metal powder fused by laser PolyJet: Polymer (multi) material deposited in layers like inkjet 3-D Printing driven by CAD Model of part(s) CAD Model done by mechanical designer (recommended) Many Service Bureaus can produce rapid prototypes quickly

8 Vast array of materials available

9 Don t rule out 3-D Printing as a manufacturing tool In the past 3 years, 3-d Printing has become viable manufacturing tool! Hybrid 3-D Print/CNC becoming vogue finished parts! GE printing 25,000 Jet Fuel Nozzles in next 4 years Complex assembly of 18 parts reduced to single operation In General, consider 3-D printing if Complex assembly of similar materials Low production volumes Customization is a key parameter (e.g. shoe insoles)

10 Conventional Mechanical Prototype Local Machine Shop capable of making mechanical prototypes from metal and plastic: Molded (inexpensively for few parts), Machined As machine shops grow, many provide rapid proto capability. Plastic Manufacturer capable of making prototypes via several methods Plastic manufacturers adopting 3-D Printing as mold-maker, cutting time and cost. Can still make prototype, with no commitment to production Regardless of prototype methodology, you must commit to production resource in later prototype stages.

11 But, what about electronics prototypes? While progress is being made in R&D for electronic 3-D printing, most efforts are immature breadboard systems. More efforts coming to the forefront, but easily 10 years behind mechanical prototypes. Proof of Concept: electronic breadboard built by engineer or technician IC s, components available from Digi-Key, others Firmware for control IC s programmable from PC Test, iterate for functionality as proof of concept Hutch s story: Functional/visual prototype with toaster oven! As design progresses: Consultant/resident electronics designer produces circuitry on 3-D CAD Appropriate files to generate PCB, network verification. Contract electronics manufacturers produce, test prototype Stay with contractor for production

12 Optical Prototypes Optical devices usually Photonic. Optical components: Lenses, mirrors, windows, filters Electro-optical: Light sources, detectors, displays Prototype: Optical breadboard for layout Built by Optical Engineer/technician Optical Components: Edmund Optical: Photonics components: Thorlabs: Designers: Upstate NY (Particularly Rochester) is rife with Optical design consultants, become part of your team! Latter stage prototypes, as production nears, requires analysis and design conducted by professionals

13 Complete System Prototype? Are you capable of integrating the entire system? You ve gotten mechanical, electronic, and/or optical prototypes Who s going to integrate? NY abounds in contract manufacturers, some specialized. Many Contract manufacturers are specialized, but partnered with counterparts for system integration.

14 Sources of help for prototype First Stop: TDO: NYSTAR RTDC, affiliated with NIST MEP. Partners capable of helping with prototype locator New York: FuzeHub: New, but building database of resources to HELP Broad: GLOBALSPEC: Yellow Pages of resources: design, prototype, Searchable database for design, prototype, components, Specialists and contacts mentioned in each area.

15 Conclusions Don t overbuild prototype! Make it what the demand requires: Proof of concept: Investor backing inventor, not appearance Visible: functional model demonstrates concept Presentation: Final Design Pre-Production: It can be produced! Seek partners with appropriate skills for prototype AUGMENT YOUR RESOURCES If you can t find partners, ask TDO.