Innovation resource pack - Design Museum

InnovationCase study: CAD/CAMat FordDesigners and engineersat Ford use computer-aideddesign and manufacture(CAD/CAM) to model theirideas, not sketches orhand-made prototypes.Design ideas are drawn onscreenand can be rotated inany direction. All the necessarymeasurements can be fed intothe computer, even the spaceto allow a spanner to get in andtighten a bolt. At any point adesigner in any part of the worldcan command a clay model tobe produced on computer-aidedmills in Britain and Germany.This is rapid prototyping ona worldwide scale.A designer using a CAD program.The image can be rotated on the screen.A computer-aided milling machinecutting a clay model.Developing ideasWhen you have chosen the best ideas from your brainstorm,you may need to sketch to combine or modify them. Whenyou have one or two good ideas to develop, you can start tomodel them.“Engineers … onlyever make one changeat a time … It is the onlyway of knowing if thechange has made animprovement. James Dyson”Rapid prototypingOnce the strongest idea has been chosen it mustbe developed in sketch or model form. StewartRobbins of 2pm prototypes flatpack designsusing a CAD program and cuts the shape ona plotter fitted with a scalpel instead of a pen.Foam model of DC07Buzz wordsFlatpack – a product sold as a kit ofparts to be assembled by the customer.The parts are sometimes, but notalways, flat.Injection moulding – a manufacturingprocess used to make complex shapesfrom thermoplastics. Plastic powderis heated until it becomes liquid andis squeezed under pressure into amould, which may be in several parts toallow the moulding to be removedwhen set. Injection moulding is veryquick and many thousands of items anhour may be produced.Integral – included in the main structureof the item; not added afterwardsLateral thinking – using intuition orinstinct to produce original andunusual ideas.Lug – a part of an object which sticksout and by which it can be connected,supported or lifted.Mill – a machine used to carve3D models.Modelling – trying out an idea on paper,computer or in 3D.Net or development - a 3D shapewhich is flattened by opening it outalong its seams. It may show fold linesand joining flaps or slots.Plotter – a machine which draws animage from a computer screen.Procurement – arranging for the rightparts and materials to be suppliedto the factory.Production engineering – designingand adapting machinery and systemsto manufacture a product.Prototyping – making a model todevelop an idea.Resilient – able to regain an originalshape or position after being pressed,stretched or bent.Technology transfer – usingknowledge about one subject to solvea problem in another.Thermoplastic – a group of commonlyused plastics which soften when heated.Thermoplastics are used for a widevariety of products such as householdcontainers (polyethylene, or polythene forshort), plastic packaging (polystyrene),toys and household appliances (ABS)and double glazing (PVC).A design and technology teacherprototypes a ‘waking-up device’ at aDesign Museum workshop with IDEO,world leaders in innovation.A Activity 7 guides you through theprocess of rapid prototyping.© Design Museum 2001