ETP 2006 – Annette Beattie

1. Design for EngineeringUnit 6 Research and DevelopmentAnnette BeattieAugust 4, 2006Research and Development • ETP 2006 – Annette Beattie • This material is based upon work supported by the National Science Foundation under Grant No. 0402616. Any opinions, findings and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the view of the National Science Foundation (NSF).

2. Research & Development • R&D used to be done by a single inventor – ex. Thomas Edison • During the 20th century, it became organized by businesses and other organizations, many sponsored by the national government. • (VCSU, 2006)

3. Research & Development • R&D is a necessity for the advancement and improvement of products and materials. • It is the driving force behind technological innovation. • It is to satisfy the consumer needs AND the companies need to make a profit. • As we accumulate knowledge, we open more possibilities for a better way. • (VCSU, 2006)

4. Research • For centuries, human knowledge was expanded through “trial and error”. • Then an accepted procedure was developed called the Scientific Method. • When the scientific method is used there is higher reliability and validity to the information. • (VCSU, 2006)

5. Research • Researching your ideas is a detailed process that can produce a wealth of information. • The key to doing research for innovation is asking open-ended questions. • These questions lead to more questions. • Lack of sufficient research will always be apparent in the quality and function of the product. • (VCSU, 2006)

6. The Scientific Method • This uses procedures that are precisely described and recorded so that another person could replicate the study to obtain the same results. • Research is often published to share the findings of the study. • (VCSU, 2006)

7. The Scientific Method • Question: Problem statement • Hypothesis: Possible solution to problem • Method: Actual testing of the solution and the exact steps and processes • Results: Documentation of testing results (good or bad) • Conclusion: Observations and knowledge gained • (VCSU, 2006)

8. Problem Solving • Recall these steps from a previous unit: • Define the problem • Gather information • Choose a solution • Test the idea • Evaluate the results • These steps follow the same procedures as the scientific method. • (VCSU, 2006)

9. Scientific Method “How to” • State the problem • Know exactly what it is. “My problem is…..” • Research the problem • What do I know and need to know? • Form a hypothesis • State a possible solution to my problem. • Test the hypothesis • Perform an experiment to see if it works • Draw conclusions from the data • Data are the results of an experiment • Repeat if necessary • Do more research! (VCSU, 2006)

10. Development • Throughout history we have gained knowledge and put that knowledge to use. • The result of this application of knowledge is called development. • It is the continuous process of refining and improving a product. • (VCSU, 2006)

11. Development • There are three parts to development: • Discovery – new insight into the uses of something that already exists • Invention – something that a person makes that did not previously exist • Innovation – taking several things that already exist and bringing them together to make a new device or process • (VCSU, 2006)

12. Product Development • Involves modeling and prototyping • Many models will be made prior to the finished product • Computer and mathematical models are commonly used • 3D models are also used • The different models are used for performance testing - testing function, design, durability, and determining processes used to manufacture the item. (VCSU, 2006)

13. 3D Models • Appearance models – models intended to show what the product would look like, but does not have functional parts • Functional models – operational models that show the function and working parts, but may not look like the finished item • Prototypes – models that function and look like the finished product (VCSU, 2006)

14. Improving • The process of improving and perfecting a product is never ending. • Why? • Consumer demand • More efficient processes • Better materials • Material costs • New knowledge • (VCSU, 2006)

15. Improving • The process of changing and searching for the best condition or solution to a problem is called optimization. • Sending a product through the development stage or even just the optimization stage over and over is called iteration. (VCSU, 2006)

16. Decision Making • There are many decisions that need to be made in regards to the final solution. • Often, short term and long term goals conflict. • You need to weigh one risk against another. • Example – you want to cross a river in the winter, there’s ice on the river, but you know the water is flowing underneath and the ice is thin, but the crossing bridge is a long way downstream. Tradeoffs and acceptable risks. (VCSU, 2006)

17. Technology Assessment • Two types • First – refers to the quality of the product and its design. (cost, dependability, function, durability, safety) • Is this technology worth the cost? • Second – addresses the societal impacts of a technological development • Is this technology in line with your personal values? (VCSU, 2006)

18. Technology Assessment • The impact that technology has on society was assessed and controlled by the Office of Technology Assessment (OTA) • OTA was established in 1972 • It was a nonpartisan analytical agency that assisted Congress with the complex and highly technical issues that affect our society. • However the 104th Congress removed OTA’s funding in 1995. • (Office of Technology Assessment, 2006)

19. Technology Assessment • We as citizens need to remember that technology issues need to be carefully weighed against the impact they have on individuals, society and the environment • Products need to be carefully designed • Consumers need to make wise choices • Citizens, through government regulations, must balance the trade-offs and the risks of future technological progress for the betterment of all people • (Office of Technology Assessment, 2006)

20. Product Life Cycle (PLC) (NetMBA, 2006)

21. PLC - Development • Products tend to go through five stages: • New product development stage • very expensive • no sales revenue • losses (Product Life Cycle Management, 2006)

22. PLC - Introduction • Market introduction stage • cost high • sales volume low • no competition - competitive manufacturers watch for acceptance • losses (Product Life Cycle Management, 2006)

23. PLC - Growth • Growth stage • unit costs reduced due to increases in output • sales volume increases significantly • profitability • public awareness • competition begins to increase with a few new players in establishing market • Prices set to maximize market share (Product Life Cycle Management, 2006)

24. PLC - Maturity • Mature stage • costs are very low as you are well established in market & no need for publicity. • sales volume peaks • increase in competition • prices tend to drop due to the proliferation of competing products • brand differentiation as each player seeks to differentiate from competition with "how much product" is offered • very profitable (Product Life Cycle Management, 2006)

25. PLC - Decline • Decline • costs become counter-optimal • sales volume decline or stabilize • prices, profitability diminish • profit becomes more a challenge of production and distribution efficiency than increased sales (Product Life Cycle Management, 2006)

26. Where on the chart would you place the following items? Play Station (first one) Decline PS2 Maturity Play Station 3 Development (releases Nov 17, 2006) Product Life Cycle

27. Product Life Cycle • Where on the chart would you place the following items? • Fax machine • Maturity • Milk • Maturity (will it ever leave this stage?) • “Chocolate” (LG cell phone) • Introduction

28. Rapid Prototyping • Rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data. • These "three dimensional printers" allow designers to quickly create tangible prototypes of their designs, rather than just two-dimensional pictures. (Palm, 2002)

29. Rapid Prototyping • Such models have numerous uses. • They make excellent visual aids for communicating ideas with co-workers or customers. • They can be used for design testing. For example, an aerospace engineer might mount a model airfoil in a wind tunnel to measure lift and drag forces. • Designers have always utilized prototypes; RP allows them to be made faster and less expensively. (Palm, 2002)

30. Rapid Prototyping • Most rapid prototypes require from 3 to 72 hours to build, depending on the size and complexity of the object. • This may seem slow, but it is much faster than the weeks or months required to make a prototype by traditional means such as machining. (Palm, 2002)

31. Rapid Prototyping • Rapid prototyping is an "additive" process, combining layers of paper, wax, or plastic to create a solid object. (Adding 0.1 mm layer) • In contrast, most machining processes (milling, drilling, grinding, etc.) are "subtractive" processes that remove material from a solid block. • RP’s additive nature allows it to create objects with complicated internal features that cannot be manufactured by other means. (Palm, 2002)

32. Rapid Prototyping • There are several types of Rapid Prototyping • Stereolithography • Laser cutting • Machining • Fused deposition modeling • Laminated object manufacture • And more…

33. Also known as 3-D printing, SL creates a plastic model from a CAD drawing. (Brain, n.d.) Stereolithography (SL)

34. The Stereolithography Process • From “How Stuff Works.com” the basic printing process of stereolithography goes like this: • “You create a 3-D model of your object in a CAD program • A piece of software chops your CAD model up into thin layers -- typically five to 10 layers/millimeter • The 3-D printer's laser "paints" one of the layers, exposing the liquid plastic in the tank and hardening it • The platform drops down into the tank a fraction of a millimeter and the laser paints the next layer • This process repeats, layer by layer, until your model is complete" Brain, n.d.)

35. An engine manifold Money clips Stereolighography examples

36. Costs of SL • The machine costs over $250,000 • The polymer runs about $800/gallon • However, you can have a company that already owns the machine run a part for you at around $55/hour. (Brain, n.d.)

37. Fused Deposition Modeling (FDM) • FDM is a layered manufacturing method that extrudes a thin bead of plastic, one layer at a time. • A thread of plastic is fed into an extrusion head, where it is heated into a semi-liquid state and extruded through a very small hole onto the previous layer of material. (Fused Deposition Modeling, n.d.)

39. Fused Deposition Modeling • After the first layer is complete, the platform lowers by one layer thickness and the process begins again. (Introduction to FDM, n.d.) • Because it uses high strength ABS plastic, it is the favored technology for prototyping plastic parts requiring strength (Fused Deposition Modeling, n.d.)

40. Fused Deposition Modeling Examples

41. Fused Deposition Modeling Machine

42. Fused Deposition Modeling • Advantages over Stereolithography – • Safer – no toxic fumes • Machines are less expensive • Faster than SL • Waterproof – ABS material • High strength • Multiple colors (Fused Deposition Modeling, n.d.) • Disadvantages • Dimensional tolerances are not as accurate • Surface finish is not as good (Introduction to FDM, n.d.)

43. Laminated Object Manufacturing (LOM) • The LOM process produces larger, high volume models more economically than other rapid prototyping methods. • Using layer building concepts, the LOM machine heat bonds a layer of paper and cuts that layer with a laser. • After the layer is finished, the machine repeats the cycle. (Laminated Object Manufacturing, n.d.)

44. Laminated Object Manufacturing

45. Laser Cutting • Laser cutting machines can very accurately produce complex exterior contours. The laser beam is 0.2 mm in diameter at the cutting surface and has a power of 1000 to 2000 watts. • Laser cutting takes direct input from a CAD drawing to produce flat form parts of great complexity. • Lasers work best on materials such as carbon steel or stainless steels. (Laser Cutting, n.d.)

46. Laser Cutting

47. Laser Cutting

48. Laser Cutting Advantages • Parts distortion is reduced as a result of the small Heat Affected Zones. • Increased ability to process materials due to the non-contacting cutting process. • Improved cutting abilities provides sealed edges and striation free edges. This is important for meeting tolerances, reducing rework, and improving the look of the piece. • Better accuracy. • Increased quality due to total part repeatability. • Virtually zero machining damage created by dross. (Laser Used for Metal Cutting, n.d.)

49. Sources • Brain, M. (n.d.). Retrieved September 9, 2006 from http://computer.howstuffworks.com/stereolith.htm • Fused Deposition Modeling. (n.d.). Retrieved September 9, 2006 from http://www.padtinc.com/rm/fdm/default.htm • Introduction to FDM. (n.d.). Retrieved September 9, 2006 from http://www.caip.rutgers.edu/~kbhiggin/VDF/FDM.html • Laminated Object Manufacturing. (n.d.). Retrieved September 9, 2006 from http://www.selecteng.com/lamin.htm • Laser Cutting. (n.d.) Retrieved September 9, 2006 from http://www.efunda.com/processes/metal_processing/laser_cutting.cfm • Laser Used For Metal Cutting. (n.d.). Retrieved September 9, 2006 from .http://www.cuttinglaser.info/ • NetMBA. (2006, August 5). The Product Life Cycle. Retrieved August 5, 2006, from http://www.netmba.com/marketing/product/lifecycle/ • Office of Technology Assessment. (2006, July 5). In Wikipedia, The Free Encyclopedia. Retrieved 13:10, August 5, 2006, from http://en.wikipedia.org/w/index.php?title=Office_of_Technology_Assessment&oldid=62215502. • Palm, William. (2002). The Learning Factory: Rapid Prototyping Primer. Retrieved August 4, 2005 from the website: http://www.mne.psu.edu/lamancusa/rapidpro/primer/chapter2.htm • Product life cycle management. (2006, August 3). In Wikipedia, The Free Encyclopedia. Retrieved 13:58, August 5, 2006, from http://en.wikipedia.org/w/index.php?title=Product_life_cycle_management&oldid=67399379. • Valley City State University. (2006). Unit # 6 Design For Engineering Reading Assignment Research and Development. Retrieved July 25, 2006 from the website: http://www.vcsu.edu

50. Standards • Standard #1: Students will develop an understanding of the characteristics and scope of technology. • [1.L] Inventions and innovations are the results of specific, goal-directed research. • Standard #4: Students will develop an understanding of the cultural, social, economic, and political effects of technology. • [4.I] Making decisions about the use of technology involves weighing the trade-offs between the positive and negative effects. • [4.J] Ethical considerations are important in the development, selection, and use of technologies.