INTRODUCTION
Definition of Prototyping
and Modelmaking ..................... 6
Prototyping is a Form of
Problem Solving ....................... 7
Modelmaking .......................... 7
Physical and Digital Prototypes ...... 7
Building by Hand and Using
Digital Technologies .................. 8
Organization of this Book ............ 9
PROTOTYPING
1 How Prototypes are Used
Exploration .......................... 11
User Testing ......................... 13
Communication ....................... 14
Design Verification.................. 16
Technical Performance Testing ....... 17
Safety Standards Testing ............ 17
Prototyping in Different
Fields of Design ..................... 18
From Start to Finish: Comprehensive
Case Studies ......................... 18
CASE STUDY Duo Gaming Family
of Products .......................... 19
CASE STUDY Lytro Camera 3.0 .......... 23
CASE STUDY ECOtality Blink
Range of Electric Vehicle Chargers .. 27
CASE STUDY Xoran Portable xCAT Scanner ...30
CASE STUDY Ecobee3 ................... 32
2 Prototyping Approaches
The Difference between
Prototyping and Manufacturing ....... 35
Material Substitution ............... 35
Iteration ............................ 36
Low Fidelity vs High Fidelity ........ 36
Workmanship and Level of Effort ..... 37
Looks-like and Works-like Prototypes . 37
CASE STUDY Candela Luau .............. 38
CASE STUDY Chair_ONE and Myto ........ 41
3 Prototyping Interactive
Electronic Products
Input and Output..................... 46
Programming ......................... 46
Prototyping Setup ................... 47
CASE STUDY Kurio Interactive
Museum Guide ......................... 48
MODELMAKING
4 Principles and Choices for Modelmaking
Principles of Modelmaking ........... 51
Choices to Consider ................. 52
5 Health and Safety
Goal ................................. 53
Hazards .............................. 53
Personal Protective Equipment ....... 57
Risk Assessment ...................... 58
6 Space and Setup
Space ................................ 59
Basic Setup .......................... 59
7 Workflow
Basic Modelmaking Workflow .......... 61
Reverse-Design Workflow ............. 63
CASE STUDY Scanning a
Clay Model Helmet ................... 66
8 Analog Modelmaking Tools
Basic Toolset ........................ 70
Handheld Power Tools ................. 72
Stationary Power Tools .............. 72
Machine Tools ........................ 75
9 Additive Manufacturing: 3D Printing
Steps in the 3D Printing Process .... 78
Technologies and Classifications .... 78
Powder-based Technology .............. 81
Material Extrusion Printing ......... 83
Vat Photopolymerization ............. 87
Material Jetting .................... 89
CASE STUDY Customization ............. 90
10 Subtractive Digital Machining
CNC Machining ........................ 92
Laser Cutting ........................ 96
11 Adhesives and Fillers
Glues ................................ 99
Tapes ............................... 100
Fillers ............................. 101
TUTORIAL Additive Modeling
with Adhesives and Fillers.......... 104
12 Paper
Applications for Paper ............. 107
Cross-Sectional Models ............. 109
Working with Paper and Board ....... 110
TUTORIAL Bread Toaster .............. 112
13 Foamcore
Working with Foamcore .............. 116
TUTORIAL Train Ticket Kiosk ......... 120
14 Polystyrene Foam
Applications for Polystyrene Foam .. 125
Working with Polystyrene Foam ...... 126
TUTORIAL Children’s Walkie-talkie... 129
15 Polyurethane Modeling Foam
Applications for Polyurethane Foam . 132
Working with PU Modeling Foam ...... 133
TUTORIAL Game Controller ........... 136
16 Thermoplastic Sheet and Extruded Shapes
Working with Plastics .............. 142
Gluing Plastics ..................... 143
CASE STUDY Adaptive Ski System ...... 146
TUTORIAL Barbecue Utensil .......... 148
17 Wood
CASE STUDY Leaning Clothes
Rack in Wiggle Board ............... 152
Applications for Wood .............. 153
Working with Wood ................... 154
18 Modeling Clay
Types of Clay ....................... 158
CASE STUDY Olme Spyder .............. 160
Working with Styling Clay .......... 161
TUTORIAL Clay Helmet ............... 163
19 Casting
Applications for Casting ........... 166
Casting Process ..................... 167
Casting Materials .................. 168
CASE STUDY Casting Comic Figures .... 170
CASE STUDY Elastomeric Wristband .... 171
20 Painting and Graphics
Color ............................... 174
Texture ............................. 175
Gloss, Matt, or Metallic ............ 175
Types of Paint ...................... 175
Preparation......................... 175
Application ......................... 176
TUTORIAL 3D Printer Part ........... 179
Labels and Decals ................... 181
21 Soft Goods: Sewn Textile Projects
Working with Textiles............... 185
Patterns ............................ 189
Textile Hardware ................... 191
CASE STUDY Biogarmentry ............. 193
CASE STUDY OSAT Filament Printing ... 196
Glossary .............................. 199
Resources ............................. 202
Index ................................. 203
Picture Credits ....................... 207
Acknowledgments ....................... 208

Now in its second edition, Prototyping and Modelmaking for Product Design, by practising product development consultant Bjarki Hallgrimsson, is essential reading for both students and design professionals.

Prototyping and ModelMaking for Product Design goes behind the scenes to illustrates how prototypes are used to help designers understand problems better, explore more imaginative solutions, investigate human interaction more fully and test functionality so as to de-risk the design process. Following an introduction on the purpose of prototyping, specific materials, tools and techniques are examined in detail, with step-by-step tutorials and industry examples of real and successful products illustrating how prototypes are used to help solve design problems. Workflow is also discussed, using a mixture of hands-on and digital tools.

This new edition includes case studies representing technological developments such as prototyping user experience and interactive electronic products, as well as a new expanded section on digital modelmaking tools, including 3D printing and laser cutting.

The first chapters of the book explain why prototyping is so important to the design process. The many uses of prototyping will be shown in the context of several comprehensive projects by some of the world's leading design firms.

The second part is an introduction to the typical materials used by designers in their prototyping efforts and how to work with them. In all cases, the approach is to use digital and manual tools in a complementary and effective fashion. Tutorials were specifically developed that underline the back and forth of digital and manual ways of working. The emphasis is on the kinds of construction that can be done by the designers themselves. Health and safety is stressed in terms of personal responsibility and awareness.

Topics covered include:Definition of prototyping and modelmakingPrototyping as a form of problem solvingModelmakingPhysical and digital prototypesBuidling by hand and using digital technologies