Engineering 11
Build & Test
ProtoTypes
Bruce Mayer, PE
Licensed Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
OutLine  Build & Test Proto’s
 Why test?
 Form, Fit & Function
 Types of tests
 Types of
Prototypes
 Test plans
 Summary
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Need for Physical Testing
 We canNOT do EVERYTHING on the
COMPUTER
 Finished parts do NOT always look the
same as designed
 Finished parts do NOT always fit
together as designed
 Finished parts do NOT always work the
way they were designed.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FORM Tests (easiest)
 Some Q’s Answered by FORM Tests
• Is the appearance “Dated” or “Stale”?
• Is the Product SIZE Acceptable?
– E.g., Too: Small, Large, Thick, Thin, Tall, etc.
• Is the Part Finish Attractive?
 FORM Test Purpose  Will the
part/product have an acceptable
appearance?
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FIT Tests (medium effort)
 FIT Test Issues
• Interference Analysis  Do all the parts in
an Assy FIT Together?
• Tolerance Analysis  Should any physical
Tolerance be Tightened/Loosened?
• Assembly Analysis  Can the Assembly
Sequence/Process be Improved?
 FIT Test Purpose  Will the parts Fit
and Assemble?
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FUNCTION Test (hardest)
 Some Q’s Answered by FCN Tests
• Does the Product PERFORM as Predicted
& Required?
• Will the Product Function in Extreme
Environments?
– e.g. Corrosion, Temperature, Vibration, etc.
• Is the Product Function
STABLE & REPEATABLE?
• Is the Product
SERVICEABLE?
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FUNCTION Test (hardest)
 Some Q’s Answered by FCN Tests
• Is the Product RELIABLE/DURABLE?
• Is the Product REPAIRABLE?
• Is the Product SAFE to use?
• Does the Product CONFORM to Codes
and/or Standards?
• Is the Product ERGONOMIC?
• Develop Operation & Maintenance Tools
and Procedures
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FUNCTION Test (hardest)
 FUNCTION Test Purpose  Determine
if the Product has a Realistic Chance
of Ultimately Being Saleable?
 ProtoType Function Testing is the FINAL
Go/No-Go Decision point prior to the
commitment of Major-$ for construction
of the Production Operation
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Phase-A Tests: Types & Timing
Formulation
“Product Concept” tests
validate product / appearance
Concept Design
“Proof of Concept” tests
validate physical principles
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Phase-B Tests: Types & Timing
Configuration
Design
Parametric
Design
Engineering-11: Engineering Design
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“Virtual prototype” tests
solid modeling CAD
“Alpha prototype” tests
actual geometry & materials
but may not use actual mfg. processes
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Phase-C Tests: Types & Timing
Detail Design
“Beta prototype” tests
parts made with planned mfg. processes
volunteer customers / panel
actual operating conditions, environment
Manufacture
“Preproduction prototype” tests
parts made with final mat’s & processes
independent labs: UL, CPSC, NHTSA
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Testing Sequence
LESS Expensive 1. Product concept
2. Proof of concept
3. Virtual (Computer) prototype
4. Alpha prototype
5. Beta prototype
MORE Expensive 6. Gamma PreProduction prototype
Need PHYSICAL
Prototype
Engineering-11: Engineering Design
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Physical
& Virtual
ProtoTypes
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Physical ProtoTypes
 Form & Fit ProtoType ≡ a replica or
model of the part showing principal
geometric features
 Prototypes differ in:
• Scale  Reduced, Full, Expanded
• Fabrication Process  Same as mfg,
Similar, Different
• Material  Same as final, Different, Similar
 Kinds of Prototypes: Traditional, Rapid
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Traditional ProtoTypes
 Clay models of new auto
body for appearance testing,
 Wood models of heavy equipment
patterns for metal castings,
 Manually machined metal airplane
wings for function testing in a wind
tunnel,
 Reduced-scale balsa-wood or foam
models of large facilities, to examine
equipment layout.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Traditional Proto DisAdvantages
 Uses tools and fabrication methods that
are labor intensive.
 Often require significant mechanical or
artistic skills.
 Take a long time to fabricate an original.
 Revisions may require complete
rebuilding of part
 Costly for duplicates.
 May not facilitate tooling design and
construction
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Rapid ProtoTyping
 Rapid Prototyping (RP) ≡ a group of
techniques used to quickly fabricate
a scale model of a part or assembly
using three-dimensional computer
aided design (CAD) data.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Rapid ProtoTyping Methods





NC/CNC Machining
Selective Laser Apparatus
Fused Deposition Modeling
3-D Ink Jet
Laminated Object
Manufacturing
 Selective Laser sintering
 Service Bureaus
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
CNC ProtoTyping (Subtractive)
WorkStation
Solid Modeling
CAD software
Saved Part
Solid model
file => *.PRT
NC code
generation
NC Machine
instruction
code file
Engineering-11: Engineering Design
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NC/CNC Machine
e.g. mill, lathe
Fabricated
Prototype
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Numerical Control Machining
 Can Do ON CAMPUS
• NC  MTT71A • CNC  MTT81A
 CAD files are converted to
NC–machine instruction codes for
automatic machining
• Part can be made of metal
• Dimensions have excellent tolerances
• Multiple copies of parts can be made easily
 Good for Form, Fit, Function Prototypes
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
CNC Part Example
 AutoMobile WaterPump Pulley
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
RP ProtoTyping (Additive)
Workstation
Solid Modeling
CAD software
Rapid Prototyper
Slicing Program
Saved Part
Solid model
file => *.PRT
Faceted
Model file
=> *.STL
RP Machine
instruction
code file
RP Machine
Engineering-11: Engineering Design
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Fabricated
Prototype
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
StereoLithoGraphy App (SLA)
projection
mirror
(xy-axes)
laser
elevator
(z-axis)
Solidified
lamina
Engineering-11: Engineering Design
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object being
prototyped
tank
PhotoPolymer
(liquid resin)
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
3-D Systems SLA 7000
(Courtesy of 3D Systems)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
SLA Example: Jaguar manifold
(Courtesy of 3D Systems)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Stereo Lithography Apparatus
 SLA Parts exhibit superior finishes
 SLA polymeric prototypes are weaker
than NC/CNCmetal prototypes
 SLA Prototyped parts are well suited for
• Form, and Fit tests.
• Some function testing
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Selective Laser Sintering (SLS)
 Uses a high power laser to sinter
together fusible materials, such as
powdered metals, layer by layer.
 Sintering is the heating and fusing of
small particles resulting in a hard
bonded material block.
 The un-sintered powder supports the
part as the layers are sintered.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Fused Deposition Model (FDM)
Filament
Spool
Drive Wheels
Head
Heater
Head motion
Molten filament
Fused Part
Table motion
Engineering-11: Engineering Design
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Table
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FDM System  Stratasys 3000
(Courtesy of Stratasys Corporation)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
FDM MotorCycle Cowling
(Courtesy of Stratasys Corporation)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Fused Deposition Model (FDM)
 FDM Parts can be made from: high
strength ABS plastic, impact resistant
ABS, investment casting wax, and some
elastomers.
 FDM ProtoTypes
parts are well suited for
• Form, and Fit tests.
• Some function testing
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
3-D Inkjet prototyping
 Glue-like binder selectively “printed” onto a
layer of dry powder, layer by layer, which
dries into a solid prototype.
 Similar process uses a print head to deposit a
thermoplastic material, layer by layer.
• Quick and inexpensive
• The processes work well as concept modelers.
• Prototypes have limited dimensional tolerances
• Somewhat fragile unless coated with a hardener
 Prototypes made with this process are
typically NOT function tested.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
3-D Inkjet ProtoTyping
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Z-Corporaton Z406 (“Inkjet”)
(Courtesy of Z-Corporation)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
3D InkJet Chrome Wheel
(Courtesy of Z-Corporation)
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
3D InkJet
Fan
Housing
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Laminated Object Manufacturing
 Laminating thin layers of paper, polymer
or sheet steel, which have been cut
using a numerically controlled laser.
 LOM prototypes can be sanded to
reduce jagged edges, but are not able
to be function tested such as for stress
or strain due to the anisotropic material
properties of the laminate.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
LOM
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
RP Service Bureaus
 Product manufacturer emails the solid
model part file to the service bureau,
typically as an *.STL file.
 The bureau uses its software to convert
the *.STL file to a “sliced” file format
specific to the selected prototyping
hardware (i.e. FDM, SLA, SLS, LOM),
 Part is fabricated along with any
duplicates.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Compare: RP & Traditional
 Shape generating compatibility – Can the
material be formed into the needed geometric
features to adequately represent the part?
 Function testing validity – Are the material
properties representative, or scalable such that the
part when reduced (or expanded) in size, can be
validly tested?
 Fabrication costs – Will the prototype costs for
materials and labor be acceptable?
 Fabrication time – How long will it take to fabricate
the original and one or more duplicates?
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Engineering Tests





Mechanical  modes of failure
Manufacturability
Operation & Maintenance
Safety
Environmental
 EngineeringTests ≠ Experiments
• Experiments validate phenomena
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Mechanical Failure Modes
 static strength
 fatigue
 deflection/stiffness
 creep, impact
 vibration
 thermal/heat
transfer
 Fluid Containment
Engineering-11: Engineering Design
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 energy consumption
or production
 friction (i.e. too
much, too little)
 wear
 lubrication
 corrosion
 life, reliability
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Manufacturability
 ProtoType Testing Provides Valuable
information on Manufacturing Concerns
• process compatibility/precision
• process technology readiness
• raw material
quality
• assembly
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Operation & Maintenance
 ProtoType Testing Provides Valuable
information on O&M Concerns
• Installation
• styling/aesthetics
• Ergonomics
• Scheduled maintenance
• Repairs
• O&M Tooling Development
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Safety Concerns
 ProtoType Testing Provides Valuable
information on Safety Concerns
• risk to user, product liability
• risk to consumer/society
• safety codes, standards (UL, NFPA, NEC)
• risk to production worker (e.g. OSHA)
• FailSafe Operation
• Seismic Restraint/Tolerance
• Etc.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Environmental Protection
 ProtoType Testing Provides Valuable
information on Environmental Impact
• Effluent Discharge:
– Gaseous  Air Pollution
– Liquid  Water Pollution
– Solid  Ground Pollution
• Loud Noise
• Intense Light
• RadioActivity
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Engineering-Test Planning
 A Good Plan for an Engineering Test Lists:
• Objectives
– list of items (parts, systems, models) to be tested
– purposes for which the tests are being conducted
• WorkScope – narrative description:
–
–
–
–
–
–
type of tests,
test descriptions/procedures,
experimental setup,
experimental controls,
design of experiments test matrix
list of deliverables.
• Budget
• Schedule
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Summary
 Companies build and test prototypes to
ensure form, fit and function.
 Product development tests include:
product-concept, proof-of-concept,
virtual, alpha, beta, and preproduction.
 Prototypes can be built using traditional
and rapid prototyping methods and
materials.
 Rapid prototyping methods include
NC/CNC, SLA, FDM, LOM, SLS,
and 3-D Inkjet printing
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Summary
 Rapid prototyping takes advantage of
CAD
 Part and product testing can include
tests for: mechanical modes of failure,
manufacturability, user operation &
maintenance, safety and environmental
protection.
 Product development often requires the
preparation and completion of a detailed
test plan.
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
All Done for Today
H.A.L.T.
Testing
Engineering-11: Engineering Design
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 HALT = Highly Accelerated
Life Testing
• HALT is used to find the weak
links in the design and fabrication
processes of a product during the
design phase.
• The stresses are not meant to
simulate the field environments at
all, but to find the weak links in
the design and processes using
only a few units. The stresses are
stepped up to well beyond the
expected field environment until
the “fundamental limit of the
technology” is reached.
Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Engineering 11
Appendix
Bruce Mayer, PE
Registered Electrical & Mechanical Engineer
BMayer@ChabotCollege.edu
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
Milestone Prototypes
 Alpha Prototypes – assess whether the
product works as intended
 Beta Prototypes – assess reliability and
to identify any bugs in the product
• May Be Placed at OutSide “ß-Sites”
 Gamma (PreProduction) Prototypes –
first products produced by the entire
production process
• May Be SOLD to OutSide Customer
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt
HALT Chamber Design
Engineering-11: Engineering Design
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Bruce Mayer, PE
BMayer@ChabotCollege.edu • ENGR-11_Lec-11_Chp9_ProtoType_Build.ppt