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Home > Technologies > Enclosures
> Tap New Technologies To Produce Practically Perfect Prototypes

Tap New Technologies To Produce Practically Perfect
Prototypes

Don’t worry if you need to deliver polished prototypes quickly
to meet looming time-to-market deadlines. Dev kits, 3D printers, and other tools
can provide immediate help.

Jan 18, 2013
William Wong

EMAIL

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Comments
2

Design cycles keep getting shorter. Developers
are using a host of technologies to meet these new deadlines. Everything from
slick development kits to complete reference designs can cut days or months from
a schedule.

Prototypes often need to meet more demanding
requirements as well, especially where mobile consumer electronics are
concerned. It’s hard to imagine how a solution works if it’s strewn across a
workbench with wires and probes attached.

The challenge for creating something closer to
an end product is often mechanical. Soldering irons rarely touch circuit boards
these days, and boards are no longer simple rectangles. Sometimes
fast-turnaround outsourcing is the answer. Sometimes it’s in-house creation of
boards and other mechanicals.

Editor's note: Gumstix's Geppetto was in beta when I wrote this
article but you can now check it out in the article I recently wrote entitled Game
Changing Geppetto Builds ARM-based Systems.

The rise of desktop solutions in
printed-circuit board (PCB) creation and 3D printing enable small design teams
and even individual designers to perform this kind of work themselves. The
resulting solution often may be almost identical to the final product. More
importantly, these solutions enable designers to quickly create new variations.
Rarely is the first version of a prototype the same as the final product.
Several iterations often are required.

Designs can change because of the way
designers see the software, hardware, and mechanicals come together. Circuit
boards may be redesigned for better system construction or information
presentation. Software may be able to take advantage of more input if additional
buttons can be included.

In the past, longer design cycles allowed this
feedback to occur. Short design cycles mean this type of change needs to be
completed more quickly. Sending something out to make each change is time
consuming and can be costly. The ability to do the job locally can cut costs
even if the additional tools are expensive.

A single designer can be a jack-of-all-trades
and deal with everything from software to board and case design. But typically,
a small design team brings the necessary expertise to bear.

Making The Mechanicals

Designers often concentrate on their area of
expertise and overlook other aspects of the design, counting on someone else to
turn out the final product. Because of the construction methods, final
production traditionally was outsourced or required a significant in-house
production facility.

Low-cost 3D printers like the Lulzbot AO-101
(Fig. 1) and the Makerbot Replicator 2x (Fig. 2) have changed the production
process. These devices cost less than a couple thousand dollars, and they fit on
the desktop. They’re also easy to use.

Figure 1. The Lulzbot AO-101 open-frame
desktop 3D printer fits on a desktop.

Figure 2. Makerbot’s Replicator 2x can
utilize a dual extrusion head, constructing objects using two different kinds of
plastic.

3D printing isn’t new, but 3D printers tended
to be larger, expensive devices requiring expertise to get good results. Those
machines are still invaluable in their application areas, allowing the creation
of objects from a variety of materials including metals. Low-cost 3D printers,
though, tend to utilize ABS or PLA plastic.

Some available 3D printing methodologies lend
themselves better to different materials such as metals. Low-cost 3D printers
like those from Lulzbot and Makerbot utilize plastic extrusion heads that build
up layers of material.

The plastic used by these 3D printers comes in
filament spools. The filament is fed into the extrusion head, which is heated,
and a tiny bead is deposited at the end of the head. The head moves horizontally
like an inkjet printhead, but it can move along all three axes. The head is
raised slightly after it completes printing the current layer.

Objects created by 3D printers are usually
limited in size by the volume that the nozzle can traverse. More expensive
printers typically support larger-volume objects. Low-cost 3D printers like the
AO-101 employ a single nozzle, so most objects are built using a single color
and type of plastic. The plastic tends to be available in a variety of
colors.

Some systems employ a dual extrusion head that
allows printing with two different materials. It could be used for two different
colors, or one of the materials might be used as a support for complex
objects.

3D printers cannot simply print an object
floating in the air. The object must sit on the build platform and be stable
while the rest of it is built. Many object designs account for this placement.
Sometimes, though, an object cannot be freestanding or it may have very limited
support capacity, making accurate printing impossible.

The object design is often modified to include
additional supports that would be removed when printing completes but before the
object is used. These supports could be made of the same substance as the
object, or they might be an additional substance that may be removed in a
variety of ways, such as mechanical removal (i.e., breaking off a part) or
dissolving in a solvent that could include water. Of course, the main substance
of the object should not be destroyed in the process.

A single-head system can build up supports
using different materials, but these materials need to be changed. A dual-head
system can handle two materials, which is often sufficient for even very complex
designs.

Another alternative to some complex designs is
the creation of multiple objects that fit together. This may be a requirement
for the overall design or it may be something that is introduced because of the
complexity of the object.

The design of an object and its supports can
have some effect on the accuracy of reproduction. Generally, though, the
printer’s capability sets the mark of quality.

Makerbot and Lulzbot have a layer thickness of
0.1 mm with nozzle diameters on the order of 0.25 mm to 0.4 mm. The build volume
for the AO-101 is 200 by 190 by 100 mm. The Replicator 2x build volume is 285 by
153 by 155 mm.

The ability to print fine detail means these
printers can create smooth surfaces that don’t require post-production work.
They also can handle small parts like gears and snap-fit connections.

3D printers, large and small, often are used
for prototype work. But sometimes, they’re used for production work where the
printer’s advantages can be employed, including the creation of complex or
custom parts. They also can be used for on-demand parts creation.

Desktop PCB Creation

Inside those new 3D printed cases for
electronic devices, there likely will be a PCB or two. Creating and revising
these circuit boards can be as daunting as creating the case. As it turns out,
some desktop solutions for creating PCBs don’t require a chemical vat.

LPKF Laser and Electronics’ ProtoMat family
works in the opposite mode of the 3D printers. (see "Build Your Own PC Board: A Designer's Dream" at
electronicdesign.com) While 3D printers build up a new object in layers, the
ProtoMat S103 is essentially a milling machine that starts with a PCB with a
solid copper layer that is then ground away (Fig. 3).

Figure 1. LPKF’s desktop ProtoMat S103
creates custom PCBs by grinding off unwanted copper from the board instead of
doing the job chemically. It can create multilayer boards a layer at a
time.

The ProtoMat’s vacuum table holds down a blank
circuit board. The milling head is moved so it can grind down the copper, which
is vacuumed away. A two-sided board is created by manually flipping the board
over and then doing the same thing to the other side. The system is accurate
enough to handle multilayer boards, though they must be laminated together. An
optical camera-based alignment system uses fiducials on the circuit board.

The approach is especially effective for PCBs
related to radio technology including the creation of on-board antenna because
of its precision. The unit can take off part of a copper layer, not just all the
copper from a designated area.

Likewise, copper just happens to be the
component removed to make a PCB. The ProtoMat is a general milling machine that
can work with almost any kind of material including plastics. If you don’t have
a 3D printer handy, it might be easier to take a stock case and cut it to
fit.

Prototype Production

Desktop PCB machines like the ProtoMat are an
order of magnitude more expensive than the 3D plastic printers, so designers may
have to turn to outside sources for PCBs. Designers have been doing that almost
since the electronics industry began, but the turnaround time has shrunk.
Likewise, the world has turned to surface-mount technology, pushing the
soldering iron into the corner of unused tools for prototypers.

Anyone who thinks a PCB is just a PCB hasn’t
looked at the technology in a while. PCB technology has always included a wide
range of options, from the number of layers to the dielectric spacing. Surface
mount, RF designs, and the European Union’s Restrictions on Hazardous Substances
(RoHS) all combine to make new PCB design a challenge.

The Internet has radically changed the way
PCBs are delivered. The ordering process from vendors like Sunstone and
ExpressPCB is streamlined, allowing extremely fast turnaround. Developers
specify the board requirements, upload the design files, and wait for delivery
of the final product.

PCB design applications available from most
PCB vendors meet the needs of many developers. More advanced tools are available
from third parties that support a range of data formats so developers canchoose
the tool that meets their requirements.

Also known as check for manufacturability
(CFM), the design rules check (DRC) normally associated with PCB tools is just
the starting point for ensuring developers get the kind of results they intend.
Design for manufacturing (DFM), which is where cutting-edge prototypers are,
typically is part of an overall product cost management (PCM) system. PCM also
includes methodologies such as design for procurement, design for assembly, and
cost targeting.

Incorporating these design methodologies into
the design cycle is important as developers deliver prototypes that are closer
to final products. It also means that the move from prototypes to production
becomes faster as well.

Designers should consider the type of support
their tools have for these methodologies. Bare-bones PCB tools often lack this
kind of support, while high-end products provide extensive support for these
processes as well as integration with other enterprise-level management
tools.

PCB assembly services often can be tied
together with PCB creation. Sunstone works with Screaming Circuits to provide
this type of service. The process is obviously more involved because parts
delivery or acquisition is added to the mix in addition to placement details and
other specifications required for assembly, but the results can be a working
system.

Again, the Internet has streamlined the
configuration and order process for simple projects. More involved projects tend
to require more personal intervention, but they also tend to be more ambitious
and more costly.

Polished Dev Kits and Reference Designs

Functional cases and PCBs are of little use if
there isn’t an application, which is where software and hardware designers
contribute to the product. Starting from scratch is a possibility, but these
days a project is likely to start from a development kit or a reference
design.

The improvements in development kits have been
remarkable. What used to be a bare board with a chip and some patch area is now
a complete kit that often includes a substantial amount of development and
diagnostic software. Open-source software and open hardware design have driven
these improvements as vendors compete to get their components adopted for new
projects.

The Eclipse integrated development environment
(IDE) is the basis for many different toolsets. Individual IDEs are likely to
have substantial customization over the base Eclipse IDE with features such as
multicore debugging, system configuration, and others that highlight the
underlying hardware.

The amount of software and its quality
continues to increase. For example, Texas Instruments released its TI-RTOS for
its development kits along with the Eclipse-based Code Composer Studio (see "New
RTOS Builds On DSP Roots" at electronicdesign.com). Freescale provides the
MQX RTOS for many of its platforms (see "MCU Exhibits Tower Power" at electronicdesign.com). It is
integrated with Freescale’s CodeWarrior IDE, which also is based on Eclipse.

Many more IDEs and operating systems are
available with various development kits. Developers rarely start with a bare
board or chip. Demo applications and other middleware including a TCP/IP stack
or a motor control library often can make a developer’s job easier.

Of course, most development kits come with
their own board support packages (BSPs), but this may not always be the case
when moving to custom or semi-custom hardware. There are a number of places to
turn when looking for most custom configurations. For example, real-time
operating system (RTOS) vendors like TimeSys build custom BSPs plus software
development kit (SDKs) and IDEs based on user selections on their Web site
configuration tools.

The open-source Yacto project provides similar
support. Many commercial vendors support and utilize Yacto’s software and tools
within their own offerings. It supports a range of architectures including ARM,
PPC, MIPS, x86, and x86-64. It also includes the core system component recipes
from the OpenEmbedded Project, which is a Linux framework. It supports a wide
range of frameworks such as GTK+, Qt, and Windows as well.

Those new to the Yacto project can give it a
whirl using the Yacto Project Build Appliance. It allows system creation using a
non-Linux platform. The software, design recipes, and other information is kept
in Git repositories that are available via the Internet, providing developers
with the latest software and source code. Using these shared resources is one
way to get a prototype up and running since developers can take advantage of
available tools and applications.

Reference designs have also improved
significantly. If you’re going to be designing a tablet, you can get reference
design kits from a number of vendors. These kits typically have some level of
expandability, so designers can customize the system. They come with the
operating system and all device drivers so developers can concentrate on their
application.

Reference designs typically provide a 90%
solution or better. Hardware can be turned into product quickly, and software
incorporates most of the underlying support from the operating system on up.

The Bug Labs BUGbase isn’t really a reference
design, but it’s often a great alternative to a less modular reference design
for mobile applications (see "Build With A Bug" at electronicdesign.com). It’s possible
to plug up to four modules into a BUGbase with an Arm Cortex-A8 inside. The
modules can be anything from an LCD touchscreen to a digital camera. Some
wireless support is built in with cellular found in a module.

Bug Labs delivers open-source hardware, so
it’s possible to turn a design into a custom product. Small runs could even be
built on the BUGbase.

Module platforms often are used by prototypers
that are more interested in adding their software to the mix. The open-source
Raspberry Pi and Arduino series are two popular platforms. Arduino started with
Atmel’s 8-bit AVR processor, and a C IDE and training environment was built
around it. Also, 32-bit Arduino platforms with the same form factor were built
to handle Arduino “shields” like Digilent’s chipKIT MAX32 based on Microchip’s
32-bit MIPS microcontroller (see "PIC32 Arduino Modules" at electronicdesign.com).

Modules offer prototype developers a way to
build custom carrier boards that are usually less difficult to design. These
boards are paired with a processor or system module that does the heavy lifting.
The carrier provides connectors, power, and possibly some custom peripheral
interfaces.

Modules like Opal Kelly’s XEM6310 series pack
in an FPGA and a SuperSpeed USB 3.0 interface. FPGA software design is still a
challenge, but this alleviates the hardware design issues.

Gumstix offers a compact module suitable for
mobile applications. In fact, Gumstix modules are used by some vendors providing
display reference designs so developers can choose from a range of processor and
peripheral options. The latest module has a dual-core Arm Cortex-A9 (see "Small Modules Deliver More Performance" at
electronicdesign.com).

Want to use the latest NVidia Tegra 4 with
four Arm Cortex-A15 cores? Odds are a module will be the fastest way for most
designers to get it into play.

Larger modules tend to come in standard form
factors. COM Express and Qseven are two standards that have a variety of modules
available from numerous vendors. They have different form factors, with more
compact versions supporting mobile applications.

Prototyping Studio

Smart-phone app development often is a
software-only chore, but even smart-phone apps often need additional hardware.
Sometimes it’s plugged into the headphone jack or the USB connector found on
many devices. The application isn’t complete without that hardware.

The 3D printers already mentioned are
sometimes an option for creating some of this hardware, but often a more robust
workshop is required to turn an idea into a prototype. Many companies and
individuals have the tools and expertise to do this, though designers often need
to turn to outside sources for help or tools.

The TechShop is one of those spots where
developers can gain access to tools and expertise that aren’t common in the
typical home or in most companies. TechShops can be found in a few major U.S.
cities like Menlo Park in California and Detroit, Michigan.

Members have access to all the tools at the
facility. If you’re looking for a common tool, TechShop will have several
available so there’s no waiting. When it comes to larger items like the
DETflowjet water jet, which can cut precisely through 6 inches of almost any
material from metal to fabric, there may be only one available so it’s a simple
matter of scheduling time to get the job done (Fig. 4).

Figure 4. TechShops members have access to a
wide range of tools in electronics labs as well as metal and wood shops. Lead
dream consultant Shawn Simone is using the DETflowjet water jet, which can cut
precisely through 6 inches of almost any material.

TechShop staff also provides training since
safe operation is important and not everyone will be familiar with every tool.
Likewise, TechShop is a good place to find a collaborator who might be able to
handle unfamiliar work or generate an object or device when you lack the time or
expertise.

TechShop isn’t restricted to mechanical work,
though it tends to be a significant portion of its toolset. Electronics and
software are part of the mix as well. Square’s iPhone credit card reader came
out of a TechShop (Fig. 5). Quite a number of other projects have evolved from
prototypes to final products through the TechShop.

Figure 5. Square’s simple credit card reader
is the type of hardware that can be easily prototyped with the right facilities
like TechShop.

Of course, prototypes can be useful in funding
new projects, and developers have been turning to Kickstarter to get funds (see
"Is Kickstarter The New Way To Get Capital?" at
electronicdesign.com). Venture capitalists are still an option, but Kickstarter
offers a way to work directly with the customer.

A project on Kickstarter can have different
types of supporters. Each supporter pledges a certain amount of money backed up
by a credit card. A project goes forward if it receives some minimal amount of
support that, in theory, provides the capital to complete the project.
Supporters typically receive something in return. For example, Ouya’s supporters
get a game console and controller (see "Ouya Brings $99 Game Console Via Kickstarter" at
electronicdesign.com).

Different levels of support can provide
supporters with different results. Ouya supporters who signed up for a more
costly level got early delivery of a development platform with development
software. Ouya already has delivered the NVidia Tegra 3-based development tools
to those supporters.

Internet Collaboration

The Internet has had a major impact in
shrinking the design cycle and raising the importance of prototype creation as
early as possible. 3D desktop printers are affordable, and remote access to them
is as common as getting a PCB generated by a third party.

Many companies are still physically located in
one spot, but it’s now possible to create virtual companies distributed across
the globe. Collaboration tools are more effective, and video conferencing can
provide face-to-face interaction.

3D printers can provide a way to distribute
designs to various locations. Even delivery of PCBs and final boards can be used
to support a disperse group of developers. Remote programming and debugging are
possibilities if a particular device is unique or difficult to replicate at
different locations.

Tools like 3D printers can be combined with
customized reference designs to turn ideas into reality. These days, products
can be produced for a lot less money, and the tools sit on the
desktop.

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Discuss this Article 2

EAF
LLC

on Feb 8, 2013

William--really great summary of a lot of facets in the process. Thanks.
Blaine Bateman

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e3belectrical

on Feb 28, 2013

Thank You William for such good information about different products. In
today's world electronic manufacturing companies have come up with many products
but your information about various facts is good.

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