product engineering
Now the concept design direction is ready, we can start building the product with 3d software and add much more technical details. This is needed to be able to make a first prototype.
more details
The next big milestone is building a realistic prototype. In order to get there, we need to go through an engineering process to translate the sketches into realistic 3D CAD models.
Manufacturing firms are unable to make parts based on sketches. Their machines need sophisticated 3D CAD models to manufacture prototyping parts.
Although the sketches of the concept have already a certain level of details, many technical solutions still need to be found, build and verified. A 3D model is the perfect tool to build, improve and test the product virtually.
modeling
The start of 3D modeling is building parts and assemblies, which will together form the product. Some parts may have very complex outer surfaces, which requires time to model and optimize in order to get the desired shape. In many cases the 3D CAD model will consist of dozens up to hundreds of parts and many assemblies.
All connections between the parts and standard components have to be included in the model, together with information about wall thickness, bosses or inserts for screws, click fingers, draft angles for molding, tolerances, material properties and many things more.
3d printing
During the creation of the 3D CAD models we continuously need to find solutions and test them. We can do many things in the virtual model itself, like checking interference with cut sections, let parts move and rotate towards each other to check kinematics.
Still, to have a part in your hand is superior. Therefore we make many intermediate 3D prints of the parts we create, to check, see in real and get inspiration for even better solutions that are easier, stronger or cheaper later in manufacturing.
materials
During the product engineering we have to select materials for each part. We have experience in using for instance bio-compatible materials like LSR (liquid silicon rubber), medical grade engineering plastics and medical metals.
In sports applications we use high performance engineering plastics, like glass filled Nylons, PEEK or simpler ABS / PC types of plastics, as well as high performance TPE and TPU’s.
Apart from plastics we have experience with metals, like copper, magnesium, stainless steel and lightweight aerospace aluminium like AL7068-T6511.
For sports applications we gained experience in both natural as well as synthetic leathers and fabrics, both for shoes and bags and carbon for bike frame manufacturing.
integration
Some products have integrated electronics, motors or electric drives. That means we need to test these parts, select the best ones for the application and build these into the 3D CAD model.
In the past we had our in-house pcb development which is still useful today in terms of understanding the integration of pcb’s in products, the limitations and possibilities.
We also write mostly a first level of software ourselves to be able to quickly test motors and controllers. Obviously, when a product prototype is build, industry grade software needs to be written.
simulations
We perform FEM simulations on parts that bear heavy dynamic or static loads or which are crucial for the safety of a product.
In many cases we perform 3D CAD simulations and tests with prototypes to achieve maximum performance at minimum weight. During bicycle design, we use kinematics simulation software to develop the solutions for rear suspension and geometry.
next step
Once the 3D CAD engineering is finished, we need to create a minimal set of 2D drawings and prototype documentation.
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