Prototype Production Research Articles

Effect of Product Prototyping on the Purchase Intention of BJ50 Among 3-Wheeler Tuk-Tuk Users in Laikipia County, Kenya

Effect of Product Prototyping on the Purchase Intention of BJ50 Among 3-Wheeler Tuk-Tuk Users in Laikipia County, Kenya

Influence of Finishing Process Parameters of HDF Boards on Selected Properties of Coatings in Modern UV Lines and Their Relation to Energy Consumption

This study analyzes the influence of energy generated by emitters on the adhesive properties of varnish coatings in multilayer UV systems. The experimental material, in the form of a cell board finished with UV varnish products, was prepared on a prototype line under the conditions of Borne Furniture in Gorzów Wielkopolski. The roughness and wettability were measured using a OneAttension tensiometer integrated with a topographic module, taking into account the Wenzel coefficient. The adhesion of the examined systems was verified using the PositiTest AT-A automatic pull-off device. Energy consumption by the prototype production line was compared to the standard line, utilizing mercury emitters and mercury emitters with added gallium. Energy consumption was calculated for selected variants. The influence of the Wenzel coefficient on the wettability angle was observed. Significant differences between contact angles (CA and CAc) were noted for coatings formed with sealers (stages I and II). The largest discrepancies, reaching up to 30 degrees, were recorded at the lowest UVA and UVV doses of 26 mJ/cm2. In adhesion tests, values below 1 MPa were obtained. Insufficient energy doses in the curing process of UV systems led to delamination between the coatings. Five variants were selected where delamination within the substrate predominated (˃90% A) and were characterized by the lowest energy consumption in the processes. Topographic images helped identify the presence of various surface microstructures at different stages of the production cycle. The greatest energy savings, up to 50%, were achieved in stages III and IV of the technological process.

Cannabinoid-Inspired Inhibitors of the SARS-CoV-2 Coronavirus 2′-O-Methyltransferase (2′-O-MTase) Non-Structural Protein (Nsp10–16)

The design and synthesis of antiviral compounds were guided by computationally predicted data against highly conserved non-structural proteins (Nsps) of the SARS-CoV-2 coronavirus. Chromenephenylmethanone-1 (CPM-1), a novel biphenylpyran (BPP), was selected from a unique natural product library based on in silico docking scores to coronavirus Nsps with high specificity to the methyltransferase protein (2′-O-MTase, Nsp10–16), which is responsible for viral mRNA maturation and host innate immune response evasion. To target the 2′-O-MTase, CPM-1, along with intermediate BPP regioisomers, tetrahydrophenylmethanones (TPMs), were synthesized and structurally validated via nuclear magnetic resonance (NMR) data and DP4+ structure probability analyses. To investigate the activity of these BPPs, the following in vitro assays were conducted: SARS-CoV-2 inhibition, biochemical target validation, mutagenicity, and cytotoxicity. CPM-1 possessed notable activity against SARS-CoV-2 with 98.9% inhibition at 10 µM and an EC50 of 7.65 µM, as well as inhibition of SARS-CoV-2’s 2′-O-MTase (expressed and purified) with an IC50 of 1.5 ± 0.2 µM. In addition, CPM-1 revealed no cytotoxicity (CC50 of >100 µM) or mutagenicity (no frameshift or base-pair mutations). This study demonstrates the potential of computational modeling for the discovery of natural product prototypes followed by the design and synthesis of drug leads to inhibit the SARS-CoV-2 2′-O-MTase.

Methodological approaches to the creation and functioning of serial robotic production of small satellites

The article considers a system approach to the creation of robotic production of small nano satellites to ensure their serial production. The analysis of key trends in the creation and development of modern satellite production was carried out; the factors characterizing serial robotic production are identified and systematized. An intelligent production cell is described as the main element of serial robotic matrix-type production. The main types of design solutions aimed at adapting the design of a small satellite for robotic assembly are presented. The description of the project to create a prototype for serial production of small satellites in the format of a cyberphysical factory, implemented at the advanced aerospace engineering school of Samara University, is given.

New Biorefinery Approach for the Valorization of Fruit Processing Waste at a Local Scale: Pomegranate Pomace as Case Study

AbstractThe processing of fruit and vegetables generates globally high amount of organic waste, which is suitable to be valorized because of the chemistry it encloses. Conventional treatment methods for waste biomass generate low value products and cause climate altering emissions. Small biorefineries are valid alternatives for the sustainable waste biomass conversion, but their feasibility is strictly related to the use of low-energy process, and the market positioning of the final product. The present work provides an innovative approach for the green conversion of vegetable waste into high value product, with the aim to encourage the deployment of biorefinery at a local scale. It involves the enzymatic disassimilation of plant cell wall into chemicals with specific functions, and their recombination in form of emulsion, as a product prototype for food and cosmetic sector. To explain the biorefinery model, we applied it to pomegranate pomace, the residue from juicing, for the recovery of oil, pectin and antioxidant molecules via enzyme assisted extraction. The process left behind 30% of the initial solid waste. Finally, the dispersion of pomegranate oil into pomegranate pectin solution as emulsifier, brought to a novel emulsion, 98.9% waste-derived, further functionalizable with pomegranate exocarp hydrolysate with high antioxidant capacity. Graphical Abstract

Innovative robotic-woven willow-clay-composite ceiling elements

Abstract The construction sector contributes 36% to global final energy use and 39% to energy-related CO2 emissions. Consequently, it is imperative to focus on quantifying and reducing environmental impacts e.g., via renewable building materials. The combination of fast-growing willow as tension reinforcement for regionally available and compression bearing clay seems a promising approach. The new attempt is based on the idea of full circularity, as the willow clay composite modules are in the first loop dismountable and can be rearranged and reused for another life cycle. When the composite material comes to its end-of-life, the materials can be theoretically fully recovered. To assess the environmental sustainability of such an innovative composite structure for the first time, a simplified cradle to grave Life Cycle Assessment is performed. The investigation is based on experimental data of the 1 to 1 scale robotically woven willow-clay-composite ceiling demonstrator. First results reveal hot spots, especially in the supply chain of the prototype production process but compared to conventional steel concrete ceiling, the innovative biobased composite is capable to function as a CO2 sink over the entire life cycle. In addition, the resource problem of timber could be circumvented accordingly.

PRINTING A «BRACKET» TYPE PART FOR AN ENERGY-EFFICIENT CAR

Additive technologies play an important role in modern automotive design and manufacturing, with their applications expanding every year. Originally used primarily for prototyping and mock-up production, 3D printing is now increasingly being used to manufacture key automotive components, with some companies offering fully 3D printed vehicles. This article analyzes the possibilities of printing load-bearing structures and the design of a key element - the electric motor mounting bracket for the TOQ car prototype. TOQ Prototype EV is an energy-efficient electric vehicle prototype being developed by the SU Racing Team from Satbayev University. The goal of the project is to create an ultra-light, durable, energy-efficient prototype vehicle with a long range of 1 kWh of energy. The use of new materials and additive technologies opens up the possibility of creating a variety of combinations, both for the production of parts with increased strength and for the use of advanced materials in the interior of the cabin. The process of prototyping an energy-efficient electric vehicle using additive manufacturing illustrates an innovative approach to improving energy efficiency and reducing energy consumption. This article details the process of designing an electric motor bracket using generative design and additive manufacturing. The study aims to evaluate the feasibility of 3D printing the load-bearing and critical elements of an electric vehicle prototype, as well as to simulate the loads when operating an electric motor with a peak power of 2 kW. Keywords: Mechanical engineering, automotive industry, additive manufacturing, 3D printing, industry 4.0, racing car, energy efficiency.

Development of Local Cultural Woven Textile Product to Contemporary Fashion Product

This research has purpose to take local woven or “Pahkahmah” which is a cultural product of the local woven of Nong Kao district in Kanchanaburi province of Thailand to develop for and applying with contemporary fashion design in order to increase its value. The process of creation in this research has 5 steps as 1. Create concept and inspiration 2. Design collections for the improved textiles 3. Create decoration technique for the improved textile and collections 4. Create the prototype collections and products 5. Evaluate satisfactory for the prototype collection and products. The improved textiles were used in making 3 collections of fashion apparels and costume accessories in street fashion for present lifestyle. Knowledge to improved and develop local Pahkahmah woven textile and the idea from prototype collections and products from this research was relayed to makers of Pahkahmah woven textile in Nong Kao district, Kanchanaburi province. Evaluation for satisfactory to the creative idea and developed textile products by representatives of Pahkahmah woven textile maker community and consumers revealed average score 4.45 with standard deviation 0.27. Knowledge from this research become a guideline for sustainable development and innovative idea for increasing commercial value to the local Pahkahma woven products of Nong Kao district community.

Orthogonal cutting of 3D printed multi-material workpiece: numerical investigation of machining forces, stress, and temperature distribution

AbstractWith the development of 3D metal printers for rapid prototyping and industrial component production, heightened attention was directed towards post-processing operations for achieving precise surface quality and geometrical tolerances for these components. This paper investigated the orthogonal cutting of multi-material 3D printed workpieces using a coated cutting tool through finite element simulation. The workpieces featured different horizontal and vertical arrangements of layers composed of aluminum 7075-T6 alloy (Al), stainless steel 316 low alloy (SS), and Ti6Al4V alloy (Ti). The study explored the impacts of multi-material composition, coating thickness, and the rake angle of the cutting tool on machining forces, stress distribution, temperature distribution, and chip formation geometry. The results revealed a bimodal chip morphology in the machining process of horizontally arranged SS layers combined with other alloys. The SS layer resulted in a relatively uniform chip formation, while layers with two other materials exhibited a serrated chip formation. In contrast, a discontinuous chip formed when combining Al and Ti materials, as well as in the horizontally arranged layers made of Al, SS, and Ti alloys. The cutting force increased by 2.26 times when cutting workpieces with the horizontal arrangement of SS and Al layers compared to those with a single Al material. For the horizontal and vertical arrangement of layers made of Al and SS, von Mises stress values over the edge of the coated cutting tool significantly increased where the tool contacted the SS layer. Additionally, the horizontal arrangement of layers made of Al and SS materials caused the coated cutting tool to exhibit an extensive temperature distribution, with the maximum recorded temperature reaching 1448 °K. Increasing coating thickness led to a decrease in maximum principal stress at the surface of the tool and a rise in temperature at the cutting edge of the insert.

Advancing laser transmission welding for additive manufacturing: A study of glass fiber reinforced polypropylene parts

Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.

A Novelty Model Employing the Quality Life Cycle Assessment (QLCA) Indicator and Frameworks for Selecting Qualitative and Environmental Aspects for Sustainable Product Development

The objective of this investigation was: (i) to develop a model that supports sustainable product development, considering the quality aspect and the environmental impact in the product life cycle, and (ii) to establish a framework to select the proportion of the share of these aspects during product development decisions. This research concentrates on achieving products that meet customer demand and have environmentally friendly life cycles. It also supports the implementation of design activities at an early stage of product development, positioning the share of quality in relation to environmental impact. The model is based on creating hypothetical prototypes of current products, and this approach concentrated on aggregating the quality (customer satisfaction) with life cycle environmental impacts (as in ISO 14040). The model was developed in five main stages, including: (i) defining product prototypes according to the modifications of quality criteria most desired by customers, (ii) assessing the quality of prototypes according to the Q quality index, (iii) prospective assessment of the environmental impacts of the life cycles of prototypes according to the LCA environmental index, (iv) methodical integration of the above-mentioned indicators into one quality and environmental indicator QLCA, and (v) analysis of possible production solutions and setting the direction of product development, taking into account both quality and environmental aspects. This research was extended with a sensitivity analysis of the QLCA indicator, after which a framework for selecting the proportion of the Q and LCA indicator’s share in product development decisions was established. The originality of this research is the ability of the developed model to facilitate eco-innovative product design and improvements while also selecting the share of qualitative and environmental aspects needed to develop sustainable products. The results provide a dynamic and effective tool for manufacturing companies; mainly designers and managers during qualitative and environmental prototyping of products commonly used by customers. The model will provide support in predicting a product that will be manufactured that will be satisfactory for customers and environmentally friendly based on LCA.

Staying positive: producing net power.

The Spherical Tokamak for Energy Production (STEP) prototype powerplant (SPP) will be a first-of-a-kind powerplant-its prime objective is to export electrical power, to the national power transmission system ('grid'), above 100 MWe. As part of a wider issue, addressing the STEP concept design, this article seeks to explore how electrical power will be generated from a spherical tokamak heat source. Accordingly, the following key functions of the SPP power infrastructure are reviewed.Cooling the tokamak: cooling the tokamak while extracting useful thermal energy.Generating power: conversion of thermal energy to electrical energy (power generation).Managing energy: management of the site-wide distribution, storage and energy export.In each of these areas, the design scope, challenges and solution spaces have been discussed. This has shaped the design of the SPP power infrastructure, which in turn has ensured a powerplant design focused on operability and performance. Furthermore, it has been demonstrated that the SPP will achieve its prime objective in generating net power, which is enabled by a unique power infrastructure. Confidence in the ability to generate net power will be refined as the design matures. Finally, this article recommends key opportunities that STEP could use to improve power generation and reduce the parasitic load of the SPP.This article is part of the theme issue 'Delivering Fusion Energy - The Spherical Tokamak for Energy Production (STEP)'.

Maturing the design: challenges in maturing a first of a kind fusion power plant.

The design, delivery and operation of a large-scale infrastructure project are challenging at best. For the Spherical Tokamak for Energy Production (STEP) prototype powerplant (SPP), the challenges increased dramatically. In addition to being a large-scale infrastructure project, it is a cutting edge, first of a kind (FOAK) technology demonstrator. The design teams are working in a volatile, uncertain, complex and ambiguous environment, where technology is constantly emerging, maturing and changing. STEP will be unlike any power plant ever built and requires the development of new technologies and capabilities, but also a novel approach to planning and maturing the design. By taking a holistic view of the engineering life cycle from the start, the programme will be better positioned to achieve an SPP that is fit for purpose and can be used to show a path to ultimate commercial viability for subsequent power plants. This paper will review the key challenges in maturing a FOAK fusion power plant and look in depth at how the STEP team are maturing the required capabilities and planning to ensure successful delivery of the SPP. This article is part of the theme issue 'Delivering Fusion Energy - The Spherical Tokamak for Energy Production (STEP)'.

Enhancing Tennis Practice: Sensor Fusion and Pose Estimation with a Smart Tennis Ball.

This article demonstrates the integration of sensor fusion for pose estimation and data collection in tennis balls, aiming to create a smaller, less intrusive form factor for use in progressive learning during tennis practice. The study outlines the design and implementation of the Bosch BNO055 smart sensor, which features built-in managed sensor fusion capabilities. The article also discusses deriving additional data using various mathematical and simulation methods to present relevant orientation information from the sensor in Unity. Embedded within a Vermont practice foam tennis ball, the final prototype product communicates with Unity on a laptop via Bluetooth. The Unity interface effectively visualizes the ball's rotation, the resultant acceleration direction, rotations per minute (RPM), and the orientation relative to gravity. The system successfully demonstrates accurate RPM measurement, provides real-time visualization of ball spin and offers a pathway for innovative applications in tennis training technology.

Computer-Aided Design and Additive Manufacturing for Automotive Prototypes: A Review

This study investigated the integration of computer-aided design (CAD) and additive manufacturing (AM) in prototype production, particularly in the automotive industry. It explores how these technologies redefine prototyping practices, with a focus on design flexibility, material efficiency, and production speed. Adopting the Preferred Reporting Items for Systematic Reviews and Meta-Analysis (PRISMA) guidelines, this study encompasses a systematic review of 28 scholarly articles. It undertakes a comprehensive analysis to identify key themes, trends, and gaps in the existing research on CAD and AM integration in automotive prototyping. This study revealed the significant advantages of CAD and AM in prototype manufacturing, including improved design capabilities, efficient material usage, and the creation of complex geometries. It also addresses ongoing challenges, such as technology integration costs, scalability, and sustainability. Furthermore, this study foresees future developments by focusing on enhancing CAD and AM technologies to meet evolving market demands and optimize performance. This study makes a unique contribution to the literature by providing a detailed overview of the integration of CAD and AM in the context of automotive prototyping. This study incorporates valuable insights into the current practices and challenges and future prospects, potentially leading to more advanced, sustainable, and customer-oriented prototyping methods in the automotive sector.

Prototype strategy, market big data and identification of latent customer needs: an organizational learning perspective

PurposeAlthough the literature provides insights into the role of experiential learning based on prototypes in identification of latent customer need, it offers different views on the role of product prototypes in improving the efficacy of learning customer need, and also neglects the role of vicarious learning in prototype-based experiential learning. In a data-rich environment, market big data create new opportunities to learn from vicarious, digitalized experiences that are not observable with prototype-based learning. Therefore, the purpose of this study is to compare the effects of product prototype strategies – basic prototype strategy and enhanced prototype strategy – on identification of latent customer needs, and determine how each prototype strategy interacts with vicarious learning based on market big data to identify latent customer needs.Design/methodology/approachWe collected data from 299 Chinese manufacturing firms via on-site surveys to explore our research question. All of our hypotheses were supported by the regression results.FindingsThis study finds that both the enhanced and basic prototype strategies (experiential learning from direct market experience based on prototyping) have positive effects on latent need identification, but the effect of enhanced prototypes is stronger. Furthermore, the enhanced and basic prototype strategies have different interaction effects with market big data (vicarious learning from indirect market experiences) on latent need identification.Originality/valueThis research extends the literature on prototype-based learning for latent need identification. It also contributes to the experiential prototype-based learning literature by exploring the role of vicarious learning based on market big data.

Parameter Optimization in FDM Filament Fabrication via Single Screw Extruder

The presence of polymer material filaments plays a crucial role in the realm of 3D printing. These filaments are utilized in 3D printing to create prototype products efficiently and cost-effectively. However, ensuring the production of high-quality prototype products necessitates the use of superior filaments characterized by consistent diameter and a round cross-section. Filaments are typically manufactured through an extrusion process using either a single screw extruder or a twin extruder. In this research, a DIY single-screw extruder was developed specifically for filament production. The main objective of this study is to generate quality filaments by optimizing the extruder parameters for various polymer materials. Three different polymers; Ethylene-vinyl Acetate (EVA), Polypropylene (PP), and Acrylonitrile Butadiene Styrene (ABS) were employed in this study. The research aimed to assess the melt flow index (MFI) to demonstrate viscous behavior and establish the ideal parameters for each material in the extrusion process. A total of 27 EVA material filament samples, 26 PP filament samples, and 26 ABS filament samples were successfully produced. Through analysis, optimal settings were identified for EVA, PP, and ABS filaments, resulting in high-quality production. The recommended parameters for producing quality EVA filaments included a temperature of 160°C, screw speed of 400 rpm, and take-up speed of 400 rpm. For PP filaments, the optimal settings comprised a temperature of 230°C, screw speed of 700 rpm, and take-up speed of 250 rpm. Lastly, ABS filament production was optimized with a temperature of 210°C, screw speed of 300 rpm, and take-up speed of 100 rpm. This project's outcomes are anticipated to have significant implications for future advancements in filament manufacturing processes.

Towards the use of virtual reality prototypes in architecture to collect user experiences: An assessment of the comparability of patient experiences in a virtual and a real ambulatory pathway

Virtual Reality (VR) enables the low-cost production of realistic prototypes of buildings at early stages of architectural projects. Such prototypes may be used to gather the experiences of future users and iterate early on in the design. However, it is essential to evaluate whether what is experienced within such VR prototypes corresponds to what will be experienced in reality. Here, we use an innovative method to compare the experiences of patients in a real building and in a virtual environment that plays the role of a prototype that could have been created by architects during the design phase. We first designed and implemented a VR environment replicating an existing ambulatory pathway. Then, we used micro-phenomenological interviews to collect the experiences of real patients in the VR environment (n=8), along with VR traces and first-person point of view videos, and in the real ambulatory pathway (n=8). We modeled and normalized the experiences, and compared them systematically. Results suggest that patients live comparable experiences along various experiential dimensions such as thought, emotion, sensation, social and sensory perceptions, and that VR prototypes may be adequate to assess issues with architectural design. This work opens unique perspectives towards involving patients in User-Centered Design in architecture, though challenges lie ahead in how to design VR prototypes from early blueprints of architects.

Eco-Innovation Method for Sustainable Development of Energy-Producing Products Considering Quality and Life Cycle Assessment (QLCA)

The sustainability of products remains a challenge, mainly due to the lack of consistent approaches for simultaneously taking into account the key criteria of the concept in the process. This research aims to develop an eco-innovative QLCA method to create new product solutions that integrate quality (customer satisfaction) and environmental impact assessment throughout the product life cycle. The QLCA method includes: (i) product prototyping according to quality and environmental criteria; (ii) prospective assessment of the quality of prototypes, taking into account customer requirements; (iii) prospective life cycle assessment of product prototypes using a cradle-to-grave approach in accordance with ISO 14040; and (iv) setting the direction of product development while taking into account the fulfilment of customer expectations and the need to care for the environment throughout the product life cycle. Owing to the lack of previous research in this area, as well as the popularity of photovoltaic (PV) panels in reducing greenhouse gases, an illustration was obtained and test of the method was carried out on the example of silicon photovoltaic panel modules (Crystalline Si PV Module). In accordance with the adopted assumptions, the results of the QLCA method test showed that the modelled PV prototypes will, in most cases, be satisfactory for customers, but they still require improvement actions to reduce carbon dioxide (CO2) emissions throughout their life cycle. These activities should be consistent so as to achieve quality that satisfies customers. The QLCA method can be used by designers, managers, and decision-makers at the early stages of design, but also during the product maturity phase for its sustainable development.

Production of X-ray absorbing ceramics and products based on them for radiotherapy of the periorbital eye region

The paper presents an innovative method for producing high-density ceramics based on bioinert tantalum oxide (Ta2O5) and eye shield products utilizing spark plasma sintering (SPS) technology. Eye shields are in high demand for protecting the cornea and other parts of the eye from ionizing radiation during periorbital eye procedures, such as laser therapy, radiotherapy, and Mohs micrographic surgery (MMS). The dynamics of consolidation of microcrystalline Ta2O5 powder under spark plasma heating conditions in the temperature range of 1000–1400 °C were investigated. The structure, phase, and elemental composition of polycrystalline ceramic samples, including the calculation of crystal structure parameters, were studied using XRD, SEM, and EDS methods. The optimal SPS parameters for achieving maximum relative density (up to 100 %) and Vickers microhardness (up to 510 H V) of the obtained ceramics were determined. The performance properties of the ceramics were examined under conditions of a session of short-focus radiation therapy applied to the periorbital facial area. A dosimetric assessment of the absorbing capacity of the ceramics under X-ray irradiation in modes from 40 to 120 keV was conducted. A prototype of a ceramic eye shield product based on Ta2O5 was developed and manufactured for the first time using SPS technology.