For centuries the process to create or enhance a product consisted of building and testing a long series of prototypes. This build it / test it / break it approach was generally repeated until a satisfactory design was identified. While effective, the process was both costly and time consuming – with these factors often limiting innovation.
Since the late 1960s technologies such as Computer-Aided Design (CAD), Computer-Aided Engineering (CAE), and simulation, have continually evolved to lessen the dependence on physical prototype testing and thus shorten development cycles. These tools allow 3D representative digital models to be created and analyzed for manufacturability, performance, durability, and reliability at component, sub-assembly, assembly, and product levels.
With up to 80% of a product’s total cost committed in the early upstream stage, design is the optimum place to locate and correct potential geometry, performance, and manufacturing flaws. Simulation not only removes much of the cost and time associated with the building and testing of multiple prototypes; but product innovation is enhanced as designers now have the time to explore design iterations.
6D founding principals pioneered many of the testing tools, processes, and methodologies that are now standard. The company’s Senior Engineer, Garth Wiley explains that while the impact of these digital tools cannot be overstated, this does not diminish the value of testing. In fact, over the past several decades, testing is largely responsible for the evolution and advancement of such tools.
“Data collected from products operating in their natural environment provides the baseline for these digital tools. Equipment operating in mining or construction environments, for example, is instrumented with sensors to capture exact loads, stresses, and conditions to which these products are routinely subjected. This data is used to drive simulation models and analysis tools to predict if a new or modified design, material choice, or application will meet performance targets,” said Wiley. “With even a relatively small sample set, engineers can project the performance of that equipment, structure, machinery, etc. over its projected life. This provides designers and manufacturers with a quantifiably understanding of the viability of that product design.”
It’s safe to say that in the foreseeable future testing and data collection will continue to develop an even greater interdependence.