G1.0 Prototype Planning and Documentation

Introduction

Before you build a prototype, you will identify your team’s need for three general resources. The first is knowledge. Knowledge can be gathered from experts as well as online and through print sources. Another is materials. The third necessary resource is tool and equipment availability. These resources must all be available in order to build a successful prototype. You may find that it is necessary to alter your final plan or design based upon a constraint that is discovered during this stage.

Equipment

• Engineering notebook
• Supply catalogs
• Example Material Request Letter
• Internet

Procedure 

Create a document to delineate the resources needed to construct your prototype. This document will be created electronically so that it can be updated as needed. Use your notes in your engineering notebook from Activity 4.1.1 to identify necessary resources. Within the document create a table for each of the three categories of resources: materials, tools and equipment, and knowledge. Examples of tables are show below. Include thorough notes in the tables describing how and when you plan to acquire materials. Show special time constraints by highlighting specific dates by which the items must be obtained and identify items that may require significant lead time to acquire.

1. Create a Bill of Materials

a. The first step in material acquisition is to specifically identify the needed item. You must be very specific. If, for example, you need an electric motor, you need to know beforehand the ratings of the motor for your application. What does the motor move? From this information, you can select from available motors. Looking at the list of all the parts of your design solution, brainstorm with your team all the materials that you will need to build it.

b. The next step is to determine if the specific item is unique to your project (in which case it will have to be fabricated) or if it already exists. If it is unique, it will have to be made from raw materials such as wood, plastic, or metal. You can make the part yourself, or you can have it made by a person or company that your research leads you to. If the part already exists, you may purchase it or try to get it donated by the manufacturing company or by someone who has one. Obviously, donation is preferred since your group has a limited budget. Using your interpersonal communication skills, you may contact an engineer, sales representative, or supervisor from a company with the item you need. Keep it local if possible. Refer to Activity 4.1.4 Professional Correspondence for tips on corresponding with potential donors.

c. Now that you have listed the materials, research the standard sizes, quantities, and cost of the different materials and determine what sizes you will use. Use a catalog or online resources, if necessary. It may be necessary for you to draw the parts to scale to more accurately determine the quantities needed. Put the information into a table. Below is one example you may choose to follow.

Bill of Materials

 2. Create a Tools and Equipment List

a. Based on your bill of materials, determine all of the tools and equipment that will be necessary in order to assemble the materials into your prototype. Consider hand tools, power tools, shop tools and specialized equipment that may not be readily available at your school.

b. Now that you have listed the tools and equipment that you will need, determine whether they are available in your lab. If they are not, identify a source from which you can obtain the tool or equipment and contact the source. Discuss arrangements for using the equipment. Refer to Activity 4.1.4 Professional Correspondence for tips on corresponding with potential donors. Document your conversation and note the important information for each tool and equipment in a table. Below is one example you may choose to follow.

Tools and Equipment

3. Create a List of Needed Knowledge

a. Consider the additional knowledge (math, science and engineering concepts) needed to ensure that your design will meet the specifications. In addition consider the skills and knowledge needed to correctly and safely assemble your parts using the appropriate tools. List the concept, skill, or information that you will need.

b. Determine if the necessary knowledge is available from a member of your group. If not, identify a source that can provide assistance with each item listed. Contact the source to ask for help and arrange a transfer of knowledge. Refer to Activity 4.1.4 Professional Correspondence for tips on corresponding with experts. Be sure to document your conversation. Below is a table that may be helpful when recording your findings.

Needed Knowledge

As you determine resource availability for your team’s project, reflect any changes to your design with notes in your engineering notebook and revisions to your final drawings.

Conclusion

1. What items pose the biggest challenge for your team and how do you plan to overcome those challenges?

2. While compiling these lists, did you have to determine an alternative plan for any items that you are concerned about acquiring?

3. Do you feel your use of materials is cost effective? If not, what could you change in order for the design to be more cost effective?

4. What steps did your team take to remain as cost effective as possible?