How to Prototype | Synapse at Hardware Workshop 2016
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The document provides guidance on prototyping, including the importance of planning, choosing the right prototype based on what is being tested, scheduling testing, and seeking expert reviews. It discusses prototyping case studies for a stadium entry system, toothbrush, and sports watch. It also provides resources for mechanical and electrical prototyping, such as rapid prototyping services, custom PCB fabrication, and assembly houses.
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How to Prototype | Synapse at Hardware Workshop 2016
- 1. HOW TO PROTOTYPE KATE RICHMOND, BRET RICHMOND SUPPORT BY MARTINE STILLMAN & JACKIE JOHANSON 1 | S Y N A P S E C ON F I N D E N T I AL
- 2. WE PROTOTYPE TO REDUCE RISK 2 | S Y N A P S E C ON F I N D E N T I AL
- 3. PROTOTYPING & TESTING GO HAND IN HAND 3 | S Y N A P S E C ON F I N D E N T I AL
- 4. The product development process The importance of planning Ask the right questions Build the right prototype Schedule Test and validation When to ask an expert Case studies Mechanical and electrical prototyping details and resources WELL COVER 4 | S Y N A P S E C ON F I N D E N T I AL
- 5. SPDPSYNAPSE PRODUCT DEVELOPMENT PROCESS 5 | S Y N A P S E C ON F I N D E N T I AL
- 6. THE IMPORTANCE OF GOOD PLANNING 6 | S Y N A P S E C ON F I N D E N T I AL
- 7. What are you trying to learn? User experience and product definition Will this design fit 95% of my target population? Is it intuitive for users to walk up to my product and wave to wake it up? Technical and engineering challenges How do I make a bluetooth antenna work underwater? Will my design generate adequate pull force? Product architecture tradeoffs How do users respond to the product size that results from the minimum viable battery life? Who are you trying to impress? Yourself, a partner, an investor, a CM, etc? ASK THE RIGHT QUESTIONS 7 | S Y N A P S E C ON F I N D E N T I AL
- 8. Now that you have your questions, WHAT TYPE OF PROTOTYPES SHOULD YOU MAKE? Looks like: Production intent size and appearance, non-functional Great for user interaction questions, and impressing key stakeholders Lower cost and lead time than functional prototypes Works like: Explores some functional aspect of the design Great for for addressing technical risk regarding functionality or performance Saves resources by not worrying about size, appearance Looks like/Works like: Captures both function and appearance of the intended design. May be created with a different method and scale from final design. Closer to a real product - answers form, interaction, and function questions Generally higher cost, longer lead time than looks like or works like MAKE THE RIGHT PROTOTYPES 8 | S Y N A P S E C ON F I N D E N T I AL
- 9. Dont forget about testing! Plan to spend a substantial amount of your prototyping time and budget on testing Testing types Reliability - drop testing, water ingress, thermal, chemical compatibility, etc. User interaction Regulatory Performance variation over multiple units Think through what can be tested on each prototype Some types of testing, particularly reliability, require representative materials and construction Can you perform multiple tests on the same unit if you go from least to most destructive to keep build quantities and costs low? Build your schedule so that test results from one prototype inform the next generation prototype Dont ignore ambiguous or negative test results and charge ahead! TEST & VALIDATION 9 | S Y N A P S E C ON F I N D E N T I AL
- 10. SCHEDULE 1 0 | S Y N A P S E C ON F I N D E N T I AL
- 11. SCHEDULE 1 1 | S Y N A P S E C ON F I N D E N T I AL
- 12. Ask for help at key decision points Once you have a prototyping plan, have a plan review Did you choose an effective, efficient approach based on the challenges you anticipate and who youre trying to impress? Are there major design or technology risks that your prototype doesnt mitigate? Have you chosen appropriate materials, processes, and components? Before releasing custom PCBs or tooling, have a detailed technical review Custom parts are expensive and have long lead times Its easy to make silly mistakes Part on PCB has wrong package size or pinout Incorrect connector orientation Overconstrained component interfaces Once youve processed the test data, have a results review If your results are ambiguous, or if there are multiple paths forward, this is a good time to consult an expert on go-forward strategy EXPERT REVIEW & FEEDBACK LOOP 1 2 | S Y N A P S E C ON F I N D E N T I AL
- 13. 1 3 | S Y N A P S E C ON F I N D E N T I AL CASE STUDY 49ERS STADIUM ENTRY CODE NAME | KEZAR
- 14. 49ERS STADIUM ENTRY (KEZAR) P R O O F O F C O N C EP T P R O T O T Y P E What we were trying to learn How do users interact with a stadium entry system? Who we were trying to impress Key stakeholders in 49ers org 1 4 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Looks like TEST & VALIDATION User interaction testing SCHEDULE 5 weeks design & build, 4 weeks test
- 15. 49ERS STADIUM ENTRY (KEZAR) 1 5 | S Y N A P S E C ON F I N D E N T I AL P R O O F O F C O N C EP T P R O T O T Y P E
- 16. 49ERS STADIUM ENTRY (KEZAR) A L P H A P R O T O T Y P E What we were trying to learn Is this a solid product design that can pass environmental testing? Who we were trying to impress Ourselves, the CM 1 6 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Looks like / works like TEST & VALIDATION Environmental, user interaction SCHEDULE 12 weeks design & build, 8 weeks test
- 17. 49ERS STADIUM ENTRY (KEZAR) 1 7 | S Y N A P S E C ON F I N D E N T I AL P O C V S . A L P H A B O A R D S
- 18. 1 8 | S Y N A P S E C ON F I N D E N T I AL CASE STUDY SONICARE AIRFLOSS CODE NAME | CHINOOK
- 19. SONICARE AIRFLOSS (CHINOOK) P R O O F O F C O N C EP T P R O T O T Y P E ( B R E A D B O A R D ) What we were trying to learn Does our pump system design work? Who we were trying to impress Philips technical team 1 9 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Works like TEST & VALIDATION Functional test SCHEDULE 8 weeks for design, 1 week machining, 1 week assembly, 1 week of test
- 20. SONICARE AIRFLOSS (CHINOOK) 2 N D P R O O F O F C O N C EP T P R O T O T Y P E ( B R E A D B O A R D 2 ) What we were trying to learn Does our overall system work? (Gear train, plunger, mixing chamber, pump, seals) Is our volumetric-similar design viable? Who we were trying to impress Philips technical team Ourselves. Does this system deliver the energy needed? 2 0 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Works like, size similar TEST & VALIDATION Functional test SCHEDULE 16 weeks for design, 3 weeks machining, 1 week assembly, 2 weeks of test
- 21. SONICARE AIRFLOSS (CHINOOK) A L P H A P R O T O T Y P E What we were trying to learn Does our housing seal design work? Do our miniaturization details work? What happens in drop testing? Who we were trying to impress The client (Philips), both technicaland executive 2 1 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Works like, looks like TEST & VALIDATION Extensive, special emphasis on drop SCHEDULE 12 weeks for design, 10 weeks for tools, 2 weeks for build, 3 weeks for test
- 22. AIRFLOSS PROTOTYPE VIDEO R A C K A N D P I N I O N 2 2 | S Y N A P S E C ON F I N D E N T I AL
- 23. 2 3 | S Y N A P S E C ON F I N D E N T I AL CASE STUDY SPORTWATCH GPS CODE NAME | CONSTANTIN
- 24. NIKE+ SPORTWATCH GPS P R O O F O F C O N C EP T P R O T O T Y P E S What we were trying to learn GPS performance, kickstart FW development Who we were trying to impress Technical stakeholders 2 4 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Works like TEST & VALIDATION GPS Performance, display & graphics SCHEDULE 6 weeks design, 2 weeks fab, used by FW team for 12 months
- 25. NIKE+ SPORTWATCH GPS P R O O F O F C O N C EP T P R O T O T Y P E S What we were trying to learn How does the proposed form factor fit our target user group? Who we were trying to impress ID and design stakeholders 2 5 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Looks like TEST & VALIDATION User fit study SCHEDULE 2 weeks design, 2 weeks fab
- 26. NIKE+ SPORTWATCH GPS P R O O F O F C O N C EP T P R O T O T Y P E S What we were trying to learn Can an FPC survive in a watch band up to our pull force spec? Who we were trying to impress Ourselves 2 6 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Works like TEST & VALIDATION Bend & pull testing SCHEDULE 2 days build & test
- 27. NIKE+ SPORTWATCH GPS A L P H A P R O T O T Y P E S What we were trying to learn Is this product ready to build at a CM? Does the GPS antenna work in form factor? Who we were trying to impress Nike (a design driven company) TomTom (a GPS performance driven company) 2 7 | S Y N A P S E C ON F I N D E N T I AL CATEGORY Looks like/works like TEST & VALIDATION GPS performance, environmental SCHEDULE 12 weeks design, 3 weeks fab, 6 weeks test
- 28. MATERIALS & RESOURCES 2 8 | S Y N A P S E C ON F I N D E N T I AL
- 29. MECHANICAL PROTOTYPING | POSSIBILITIES & PURPOSES 2 9 | S Y N A P S E C ON F I N D E N T I AL TIME COST QUANTITY HOW REPRESENTATIVE? COMMON PURPOSES RAPID PROTOTYPING (Additive manufacturing) Overnight-3 days Cheap $100s <10 Not very. Critical to consider the purpose of the proto, because there are significant tradeoffs between processes - Fit and interface checks - Form studies - User experience testing - Appearance models (if finished) - Functional testing MACHINING 1-2 weeks Highly variable <~30 Quite. Available in a range of materials (metals, plastics, foams) - Tight tolerance requirements - Fit and interface checks - Functional testing - Performance testing - Reliability testing URETHANE CASTING 1-2 weeks Fairly cheap $500 - $3k <50 Very. Great for middle quantities, with quick timelines. High quality finish is possible - Form studies - Appearance models (if finished) - Functional testing - Performance testing INJECTION MOLDING 4-15 weeks Expensive >=$5k >100 1:1. Can use mass production materials, so appropriate for mechanical testing and cosmetic evaluation - Fit and interface checks - User experience testing - Cosmetic models - Functional testing - Performance testing - Reliability testing
- 30. Resources for Rapid Prototyping: Proto Labs: Prototyping Process, Choosing the best process for your project Quickparts: Process Comparison Chart Fabrication Partners: MECHANICAL PROTOTYPING | RESOURCES & PARTNERS 3 0 | S Y N A P S E C ON F I N D E N T I AL Additive Manufacturing and Cast Urethanes: Fathom (Seattle, WA & Oakland, CA) Fictiv (SF, CA) ProtoCafe (Redwood City, CA) 3DS Quickparts CNC Machining: Concept Reality (Vancouver, WA) Made3D (Kirkland, WA) Livewire Prototyping (Vancouver, WA) Prototype Injection Molding: Model Solution (S. Korea) AIMMCO (Woodland, WA) Fathom (Seattle, WA & Oakland, CA) Sheet Metal: Form Factor Design (Boise, ID) Peridot Corp (Pleasanton, CA)
- 31. Hobbyist boards from Sparkfun, Adafruit Great for quick proof of concept investigation Evaluation boards from semiconductor manufacturers Great for getting your firmware team up and running with production intent parts while you work on custom PCB design Modules Gumstix, Variscite, Phytec for embedded computing platforms Silicon Labs, for WiFi and Bluetooth modules Radio modules often come pre-certified! Can be used for prototyping or in low to medium volume production Semi-customized boards Gumstix Gepetto Batteries Powerstream for lithium polymer ELECTRONICS PROTOTYPING | OFF THE SHELF COMPONENTS 3 1 | S Y N A P S E C ON F I N D E N T I AL
- 32. Custom Rigid PCBs through Batch Service Assemble multiple PCBs onto a single panel Fixed quantity of prototypes (e.g. 3), limited to 2- and 4-layer designs Longer turn times (2-3 weeks) Vendors: OSH Park Custom Rigid PCBs on Dedicated Run Panels fabricated with multiple instances of your design Arbitrary number of layers, quantities, higher precision, higher cost 2-5 day turn time Examples: Prototron, APCT Custom Flexible PCBs on Dedicated Run Longer turn times (1-2 weeks) and higher cost (~2x) than rigid PCBs Examples: Streamline, Cordova ELECTRONICS PROTOTYPING | CUSTOM PCB FABRICATION 3 2 | S Y N A P S E C ON F I N D E N T I AL
- 33. Do-It-Yourself Design in components with suitable packages (e.g. >0402, no BGAs) Can reflow and rework using hot air gun for fine pitch Kitted Order with Assembly House Parts may be hand placed for low quantities, automated placement for higher volumes You supply PCBs and components Finished boards are inspected for quality Examples: PCA, Out of the Box Manufacturing, Screaming Circuits Turnkey Order with Assembly House Assembly house will order components and PCBs and deliver finished PCBAs Some fabrication vendors will provide an all-in-one service Examples: Out of the Box Manufacturing, Schippers and Crew, Screaming Circuits ELECTRONICS PROTOTYPING | CUSTOM PCB ASSEMBLY 3 3 | S Y N A P S E C ON F I N D E N T I AL