Block C – Prototypes

Context

The purpose of building a prototype is to demonstrate the targeted characteristics of a finished product to the client. Tool and die makers develop prototypes prior to the production tooling or part development. They inspect and evaluate prototype function to ensure design criteria are met and manufacturability is confirmed and tested.

Trends

Rapid prototyping (3D printing) is quickly becoming a common process within the industry. Rapid prototyping is a method of prototyping with polymers or powdered metal materials which takes only a few hours, compared to other prototyping processes which can take a few weeks.

Nanotechnology is more often being applied in the development of new materials to make them stronger and to optimize their durability.

Related Components

All components apply.

Tools and Equipment

See Appendix A.

Task 11 Develops prototype.

Required Knowledge

• K 1 types of alignment tools such as indicators, sine bars and gauge blocks
• K 2 types of clamps
• K 3 work holding devices such as vises and V-blocks
• K 4 types of fasteners such as screws and rivets
• K 5 types of adhesives such as temporary and permanent
• K 6 types of solder such as hard and soft
• K 7 types of fits such as interference and running clearance
• K 8 types of joints such as lap and dovetail
• K 9 material characteristics such as hardness and weight
• K 10 types of materials such as composites, woods and metals
• K 11 fabrication methods such as electronic modeling, hand forming, machining and rapid prototyping

Sub-task - C-11.01 Selects prototyping technique and materials.

Key Competencies

• C-11.01.01 determine materials by matching prototype application with material characteristics according to resource availability
• C-11.01.02 choose fabrication method such as electronic modeling, hand forming, machining and rapid prototyping according to job requirements and resource availability
• C-11.01.03 determine fastening and joining techniques such as adhesive bonding, soldering, welding and mechanical fastening

Sub-task - C-11.02 Fabricates prototype components.

Key Competencies

• C-11.02.01 apply chosen fabrication method such as electronic modeling, hand forming, machining and rapid prototyping
• C-11.02.02 draw sketches of prototype and component layout showing views of part relationships and assemblies
• C-11.02.03 prepare components for any special treatment such as heat treating and coating according to client requirements
• C-11.02.04 prepare components for assembly with hand finishing techniques such as filing, polishing and honing
• C-11.02.05 inspect components to ensure conformance to sketches and drawings

Sub-task - C-11.03 Assembles prototype components.

Key Competencies

• C-11.03.01 select and use tools and equipment such as clamps, indicators, wrenches, welding equipment and presses
• C-11.03.02 set up components in relation to each other according to prototype sketches and drawings
• C-11.03.03 develop special tooling aids such as clamps and fasteners
• C-11.03.04 attach components to each other by fastening, welding and bonding

Task 12 Proves out prototypes.

Required Knowledge

• K 1 types and uses of measuring equipment
• K 2 principles of metrology
• K 3 dimensional specifications such as clearances and tolerances
• K 4 prototype specifications such as written instructions, electronic drawings, photographs and sketches
• K 5 prototype application
• K 6 types of physical tests such as motion, load and fatigue
• K 7 industry standards such as International Standards Organization (ISO), ANSI and CSA
• K 8 associated systems such as pneumatic, electric and hydraulic

Sub-task - C-12.01 Inspects prototype.

Key Competencies

• C-12.01.01 select and use measurement equipment such as vernier calipers, indicators and CMM to confirm physical and geometric specifications
• C-12.01.02 perform visual inspection to confirm appearance according to client requirements
• C-12.01.03 verify components’ movements and interactions to ensure no interferences
• C-12.01.04 ensure completeness of prototype prior to final evaluation
• C-12.01.05 prepare quality assurance documentation to meet performance standards and traceability

Sub-task - C-12.02 Evaluates function of prototype.

Key Competencies

• C-12.02.01 prepare prototype for evaluation by making it ready for operations such as mounting on a press, and installing pneumatic, electric and hydraulic systems
• C-12.02.02 try out prototype functions to ensure specifications are met
• C-12.02.03 diagnose malfunctions of prototype by means such as visual inspection, measurement and documentation to isolate the problem

Sub-task - C-12.03 Resolves malfunction of prototype.

Key Competencies

• C-12.03.01 fix identified problems by disassembling, modifying and repairing affected components
• C-12.03.02 confirm functionality of altered prototype by repeating evaluation procedures