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CHAPTER 6 – PROTOTYPING, TESTING AND REFINEMENT

Case Study of Product Development

6.1 Building Prototypes
Most of the questions regarding the three major categories of product development that consists of
form, fit, and function can be tested by the conclusion of each design process stage from problem
formulation, conceptual design, configuration design, and parametric design to detail design. In
relation to that, a prototype of the product has been constructed at the earlier phases of the product
development process, before the final product is selected and proceeds to the manufacturing phase.
The purpose of the prototype is to confirm that the design satisfies all customer
requirements and performance criteria (Dieter, 2000). Therefore, several prototypes have been
constructed during the development of our product (Small capacity engine racing vehicle) as
follows:

6.1.1 Product Concept Tests

In relation to validate the problem formulation of our project and to show the appearance and
exterior of our finished product, a reduced-scale model of the proposed product was fabricated, as
shown in Figure 6.1.

Figure 6.1: Product concept of Small capacity engine racing vehicle

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6.1.1.1 Process Involved: Material used

The body of the prototype of Small capacity engine racing vehicle was fabricated by using a thin
sheet of aluminium. Meanwhile, four tires were assembled to the body of the prototype that
available in the market.

6.1.1.2 Process Involved: Cutting process

The sheet of aluminium with the thickness 0.15mm was cut out into the required dimensions using
scissors. The required dimensions was referring to the intended scale of the product where scale
1:20 has been applied.

6.1.1.3 Process Involved: Joining process

The pieces of aluminium with the intended dimensions for specific purposes were assembled to be
the complete prototype by joining them using aluminium glue.

6.1.1.4 Process Involved: Painting

In the final step of making the prototype for product concept test, the assembled prototype was
painted based on the intended colour of the future product using water colour sprays. Three colours
were used include red colour for the whole body, black colour for the stripes and tires, and white
colour for the rim, as shown in Figure 6.2.

Figure 6.2: Painted prototype with intended colour for future finished product
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6.1.2 Proof-of-Concept Tests

In relation to validate the conceptual design of our project and to prove the function concept or
performance of our finished product, a prototype of the critical part of the product has been built, as
shown in Figure 6.3.

150cc Engine

Damper / absorber

Basement / supporter

Figure 6.3: Proof-of-concept of Small capacity engine racing vehicle

6.1.2.1 Process Involved: Selected critical component

Three components have been selected in the test of proof-of-concept; 150cc Engine,
Damper/absorber, and Basement/supporter. These components are related to each other to provide a
very important function and performance to our future product.

6.1.2.2 Process Involved: Setup process

The 150cc Engine was assembled in the chassis of the product and supported by the
Basement/supporter part under the 150cc Engine. Then, Damper/absorber was installed on the
150cc Engine with the chassis of the product.

6.1.2.3 Process Involved: Running process

The assembled components were tested by running the 150cc Engine. Then, analyses were made by
observing the capability of the Basement/supporter part to support the 150cc Engine and also the
Damper/absorber to absorb the vibration made by the 150cc Engine.
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6.1.2.4 Process Involved: Refinement and Conclusion

From the analyses of running process, the used Damper/absorber needs to be refined by changing
the quality of absorbing. Meanwhile, the Basement/supporter part needs to be refined by structuring
the Basement/supporter using three bars in the middle where the previous structure using two bars
in order to reduce the vibration of the 150cc Engine.

6.1.3 Preproduction Prototype Tests

Preproduction prototype is tested in the conclusion of manufacturing phase. In relation to that, a
full-scale product made and assembled with final materials and manufacturing processes was built,
as shown in Figure 6.4. The prototype is built on finished product similar to the customer
requirements and these tests confirmed the actual performance of the final product.

Figure 6.4: Preproduction prototype of Small capacity engine racing vehicle

6.1.3.1 Process Involved: Drilling process

A conventional drilling machine was used (Figure 6.5) to cut holes into or through several metal
components, for example, making a sprocket, holes’ bolt and nut, pedals, etc.
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Figure 6.5: Drilling process

6.1.3.2 Process Involved: Grinding process

A hand grinding machine was used for grinding a rough surface and unintended shape or edges of
the fabricated components, as shown in Figure 6.6. This process made all components in good and
safe condition for assembling process to the workers.

Figure 6.6: Grinding process

6.1.3.3 Process Involved: Welding process

After the special-purpose parts were fabricated, the next step for assembling process was welding
process. A welding process, as shown in Figure 6.7, was used to join separate parts into a single
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part. In this product, all components were assembled together using welding method because of the
components used are made from mild steel, stainless steel, and high strength steel.

Figure 6.7: Welding process

6.1.3.4 Process Involved: Installing body panel

Once the chassis of the product was structured along with the interior components, the panel of the
body that made from aluminium sheet was installed, as shown in Figure 6.8. The installation was
using a rivet method between the panel and the chassis.

Figure 6.8: Installing body panel

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6.2 Final Product Prototype

Figure 6.9 shows the final product prototype of the finished product. It consists of the assembled
fabricated parts with standard parts, sub-assemblies, and then configured all components into a
complete product. This prototype has been developed successfully by following all steps in the
design process, and can be operated as our main objective that to develop a Small capacity engine
racing vehicle.

Figure 6.9: Final prototype of the product