The biggest challenge with traditional prototyping is the cost and time it takes to build and refine physical models. Designers have to produce multiple prototypes – eliminating flaws after each subsequent one – before reaching an acceptable version. This not only delays product development but also increases the risk of product failure post-launch due to limited testing under real-world conditions.
That is where scientifically accurate virtual prototypes come in. Virtual prototyping solves these challenges by allowing designers to identify flaws, test performance and refine designs before building the first physical model. That saves money and significantly shortens the product development timeframe. No wonder there is a consistent increase in demand for these virtual prototypes.
What is a Scientifically Accurate Virtual Prototype?
A scientifically accurate virtual prototype is a digital model that behaves the way the product would in the real world. In simpler terms, a virtual prototype becomes scientifically accurate when it not only represents the model’s shape but also simulates its performance under actual operating conditions.
The key elements tested in this scientific approach include structural integrity, thermal performance, fluid dynamics and material behaviour. Of course, each product has its own set of factors to be tested depending on what it is designed to do.
For instance, a sports car body designer would focus more on flow mechanics for aerodynamics, while an electronics engineer might prioritise thermal performance and material behaviour. The key is tailoring the simulation to reflect the product’s real-world use case, providing relevant insights that guide design decisions.
The Role of Simulation Tools in Enabling Scientifically Accurate Virtual Prototypes
When it comes to virtual prototyping, the real heroes are the simulation tools used in the process. These specialised software applications are what engineers use to test how a product will perform under real-world conditions (before they even build a physical prototype). They create a virtual environment where you can subject your 3D model to elements like stress, heat, motion, fluid, etc.
The product design process involves a lot of testing and tweaks before you get the final product. Simulation tools allow designers to run multiple ‘what-if’ scenarios to see how different designs of the same product will perform under varying conditions. Everything is done digitally, meaning the tweaks in designs and changes in conditions need only a few clicks on the mouse and keyboard, significantly speeding up iteration.
Importance of Simulation Tools in Product Development
1. Streamlines the Iteration Cycle
Simulation tools are essential to streamlining the iteration cycle. They allow designers to identify flaws in models and make the necessary changes to fix them. The feedback after every tweak is also instant, which essentially eliminates the back-and-forth involved with building and rebuilding physical prototypes.
2. Enhances Early-Stage Decision Making
With traditional prototyping, it is a bit tricky to know how viable a product (or its feature) is before developing the first prototype. But, when prototyping virtually, you can test viability at the concept stage, catching any potential design failures before investing in production. That allows designers room to abandon impractical design ideas before it is too late and a lot of investment has been put into them.
3. Eliminates Trial and Error
Simulation tools also replace trial and error with data-driven validation in product development. With traditional prototyping, making a prototype involved a lot of guesswork and heavy reliance on an individual’s knowledge of physics. Virtual prototyping uses real physics to test designs, ensuring the tweaks made to the models are based on informed, reliable insights.
Benefits of Scientifically Accurate Virtual Prototypes in Product Development
1. Improved Product Quality
The main advantage of a scientifically accurate virtual prototype is that it ensures a high-quality end product. Think of the prototype as a digital equivalent of the final product you will replicate for mass production. It is no longer just a mock-up but a performance-validated model that can stand up to all the elements the real product will come across in the real world.
By the time the team arrives at that final prototype, they have tested and refined various critical aspects for optimal performance. And since everything is done digitally, there is more flexibility to explore multiple design variations than would typically be feasible with physical prototypes.
2. Faster Time-to-Market
Another benefit of scientifically accurate virtual prototypes is reduced time between conceptualisation and putting the product on the market. Under a traditional approach, product development takes years to design and produce. In this case, the design phase typically takes a bigger chunk of the time because it only includes creating a physical prototype between each test.
Virtual prototypes can reduce the time required for the design phase by clearly drawing the line between design and production. Designers no longer need to step back and produce a redesigned physical prototype whenever they need to make changes.
3. Reduced Product Development Costs
In addition to reduced time, scientifically accurate prototypes also lower the cost of product development, sometimes by more than half. It has made that possible in several ways – primarily by reducing the need for multiple physical builds. With fewer physical prototypes, companies will spend less money on materials, tooling and workforce.
Additionally, the reduced timeframe also means that product development will not drag on for longer than it needs to. That translates to resource optimisation, ensuring you can shift your team and investments toward the next project even faster.
4. Reduced Post-Launch Failures
Last but not least, a scientifically accurate virtual prototype can help reduce the risk of post-launch failures – a common issue with the traditional prototyping approach. As mentioned, simulation tools replicate how the model will interact with the elements in the real world. That way, the product will be less likely to suffer issues after release.
It is also worth noting that virtual prototyping makes the design phase a lot easier for teams. That means there is a reduced likelihood of guesswork and cutting corners, which often manifest as failures in the end product post-release.
Conclusion
More companies are shifting towards virtual prototyping because it significantly increases the chances of scientifically accurate prototypes. The approach also reduces the cost and time it takes to turn a concept into a complete product that goes into the market. However, to make these benefits your reality, you must invest in the right simulation tools. So, take your time to research and compare available options before picking one that not only suits your needs but also stays within your budget.
