Quick Study - Mock-Up Model CPAP (Continuous Positive Airway Pressure) Sleep Respirator Device/Tranquility® Quest Respironics Corporation, GA formally Healthdyne Technologies, Inc.

    Quick study and crude mock-up models are a powerful tool to evaluate 3D design  using a light density (modeling foam) fore boards (foamcoreR) which can be generated quickly.  Mock-up modeling is a way to visualize a product or machine layout. It is typically constructed of cardboard or foam core®, plywood, acrylic, with fabricated joints using glue, tape, screws and staples.   The intent is support evaluating the over all full size, relating to functional component layout, human factors, user-interface, motion and interaction tasks.  It is usually modeling primary exterior and interior feature or components including enclosure walls.  Evaluation may include functional size, height and user interface requirements.

Materials: 1, 2 & 3 ply cardboard, plywood 1/8”’– 1” Stock OEM Stock – acrylic or polycarbonate sheet, bar, tube, C & U channels (See Materials Engineering)

Size limitations: unlimited    Accuracy: +/-  0.10”  -  0.25”

Basic Steps: Shop Drawing, Structural framing / panel layout, panel – joint attachments, sub-assembly (major components), final assembly finishing – clean-up

Limitations: non weight bearing construction, usually not very sturdy or transportable.  Photography usually used to document the results.
 

		Form Study – Model Handheld Terminal - Painted Foam Mock-Up Button Panel RF Terminal  LXE® Corporation, GA

     Form studies and styling explorations using a medium density foam (modeling foam board) can be generated to relatively quickly, visualize a particular concept or to verify a styling design prior to 3D CAD Modeling and prototyping.  The intent is support evaluating the final design; form, color semantics and geometry, relating to industrial design, styling, aesthetics and functional component layout,  human factors, user-interface, motion and interaction tasks and perceived value.

Materials: urethane foam / board 2-5", Foamcore 3/16" white board,  Sintra PVC 3/16"- 1/2" foam board, plywood, acrylic, Stock OEM Stock – metal or commodity plastic; ABS, PE, PET, PC (polycarbonate), nylon, available sheet, bar, tube, C & U channels (See Materials Engineering)

Size limitations: unlimited    Accuracy: +/-  0.10”  -  0.25”

Methods of fabrication:  Does not always require 3D CAD modeling

SLA-SLS  for 1- 10 prototypes 1 unit =highest cost / 2-10 units much lower unit cost

Sheet metal (CAM – CNC) great for 1- 100 prototypes and small production runs with little custom tooling expense. 1 unit =highest cost / more units = lower unit costs

Machined wood, metal / plastic (CAM – CNC) machining from solid blocks of wood, metal, sheet aluminum or steel or commodity plastic.  Quantities tend to be small; sometimes only one unit of a custom design is required.  Piece part costs are generally high, 1 unit =highest cost / more units = lower unit costs, no cost for custom tooling  

Basic Steps: 3D CAD model, shop drawing, CNC programming, CNC cutting or machining combined with custom hand work, assembly, fastening, finishing – clean-up.   Primer & painting - product graphics upon request

Limitations: non appearance construction