A versatile virtual prototyping system for rapid product development

This paper presents a versatile virtual prototyping (VP) system for digital fabrication of multi-material prototypes to facilitate rapid product development. The VP system comprises a suite of software packages for multi-material layered manufacturing (MMLM) processes, including multi-toolpath planning, build-time estimation and accuracy analysis, integrated with semi-immersive desktop-based and full-immersive CAVE-based virtual reality (VR) technology. Such versatility makes the VP system adaptable to suit specific cost and functionality requirements of various applications.The desktop-based VR system creates a semi-immersive environment for stereoscopic visualisation and quality analysis of a product design. It is relatively cost-effective and easy to operate, but its users may be distracted by environmental disturbances that could possibly diminish their efficiency of product design evaluation and improvement. To alleviate disturbance problems, the CAVE-based VR system provides an enclosed room-like environment that blocks out most disturbances, making it possible for a design team to fully concentrate and collaborate on their product design work.The VP system enhances collaboration and communication of a design team working on product development. It provides simulation techniques to analyse and improve the design of a product and its fabrication processes. Through simulations, assessment and modification of a product design can be iterated without much worry about the manufacturing and material costs of prototypes. Hence, key factors such as product shape, manufacturability, and durability that affect the profitability of manufactured products are optimised quickly. Moreover, the resulting product design can be sent via the Internet to customers for comments or marketing purposes. The VP system therefore facilitates advanced product design and helps reduce development time and cost considerably.