10 Jan Rapid Prototyping for Speed to Data
At Key Tech, we recognize the importance of being able to prototype quickly. Out-of-the-box ideas often require prototyping and testing to determine viability, and rapid prototyping allows us and our clients to efficiently reach a yes/no decision on if an idea is worth pursuing further. This helps us maintain critical project schedules and saves money for our clients by minimizing investment in concepts that are ultimately not feasible. After all, if an idea is going to fail, it is much better for it to fail fast than to fail slowly. Read on to learn more about just a few of the ways we expedite the prototyping process.
Creative Sourcing
One challenge when prototyping quickly can be sourcing long lead time components. On a recent project that had a particularly constrained problem, we came up with a creative idea that required the use of Bowden cables (a system for transmitting motion using a small inner cable that moves inside a flexible outer housing, perhaps most commonly seen on bicycle brakes). Industrial, custom Bowden cables can have relatively long lead times that were not compatible with our project schedule and would have limited the pace of prototyping. So, what did we do instead? We purchased off-the-shelf bicycle brake kits and designed our prototype to work with the mechanical brake cables. Doing so allowed us to get the parts we needed in only a couple of days. We quickly determined that the concept was feasible, effective solution and that additional investment in the idea would be worthwhile.
Note that this is far from the first time that Key Tech has gotten creative with sourcing components from completely different industries in order to rapidly prototype. Check out this May 2020 blog about getting a prototype together in under a day by leveraging the power springs found in a toy car!
Shop Local (or In House)
For custom mechanical components, we have a wide network of vendors that we utilize for a range of fabrication processes. There are many vendors that we regularly work with to fabricate quick-turn machined or 3D-printed components. However, when a prototype design requires a more complex, high tolerance, or uniquely finished component, we can rapidly fabricate components by turning to local, Baltimore-area vendors. On recent projects, I have sourced extremely high tolerance, custom rotary shafts, machined components, and sandblasting services with one- or two-day lead times by working with vendors in our city. Added benefits included supporting our local community and not having to wait on shipping times because I was able to pick up parts in person as soon as they were ready.
When we are trying to minimize schedule and prototype rapidly, we will leverage as much of our in-house capabilities as possible. For mechanical assemblies, this may mean using acrylic sheets that we cut on our laser cutter, or semi-customized aluminum parts with features added using our mill. When prototyping speed is important, using these in-house capabilities can win out over outsourcing.
In-house assembly of electrical components, such as PCBAs and custom cables, is also critical to rapid development of prototypes. These components have notoriously long lead times, but when either fully or partially assembled in-house by our electrical engineers or skilled technicians, they can be obtained in record time. For example, on one recent project, we were able to save two days by assembling components to a prototype’s PCBs on our own rather than using an external vendor. In some cases, this makes all of the difference in a project schedule.
Custom Software Tools
Key Tech has developed a custom software tool, called Key#™, which was built specifically to reduce time to testing for prototypes. Easily customizable to unique design needs, Key#™ can save an average of 1-2 months on the front end of a program, allowing for prototypes to be up and running and collecting data as quickly as possible. As described in a previous article, it’s a communication protocol, a user interface, script-based instrument control, data collection, and common data visualization, all rolled into one software application. Key#™ is straightforward to use, allowing non-software engineers to easily communicate with embedded firmware that is run on devices.
To further improve Key#™ functionality, Key Tech recently released a plugin for Key#™ called the Multiplex Module that allows Key#™ to interface with multiple off-the-shelf devices at once, such as pumps, scales, or motors. This dramatically reduces the development time needed to begin testing and data collection for a custom prototype.
Do you need help with a prototyping project? Reach out to us at TalkToUs@keytechinc.com.
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