Analytics-Driven 3D Prototyping for Faster Product Reliability Fixes

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Solution Overview

Problem

Manufacturers face challenges in rapidly addressing user concerns and feedback for complex products due to inadequate field testing and limited ability to customize and deliver product prototypes, leading to delayed responses to customer satisfaction and increased time and cost in getting products to market.

Innovation Solution

A method and system for automated prototype creation based on analytics and 3D printing, which collects and analyzes user-reported data to identify product issues, correlates factors affecting these issues, and simulates modifications to create 3D printed prototypes that address specific problems, allowing for rapid validation and customization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manufacturers conduct extensive field testing before product launch, then product reliability improves, but time to market increases

Engineering Contradiction:

Improveproduct reliabilityVSAvoidtime to market

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary analysis of user-reported data and simulates potential failure scenarios before actual product deployment. By identifying and addressing potential issues through data analytics and simulation in advance, manufacturers can reduce the need for extensive physical field testing while maintaining product reliability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates virtual copies of products through simulation models that replicate real-world operating conditions. These digital twins allow manufacturers to test product performance and reliability in virtual environments, reducing the need for physical prototypes and field testing while accelerating time to market.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If manufacturers customize and deliver personalized prototypes to users, then customer satisfaction improves, but manufacturing complexity increases

Engineering Contradiction:

Improveprototype customizationVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system enables customization of prototypes by modifying design parameters based on user feedback and reported issues. Instead of creating entirely new custom products, the system adjusts specific parameters of existing designs, reducing manufacturing complexity while maintaining adaptability to user needs.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system pre-processes user feedback and prepares customized prototype designs before user requests. By analyzing reported data and generating potential design modifications in advance, the system reduces the complexity of on-demand customization and enables faster delivery of personalized prototypes.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If manufacturers rapidly iterate on product designs based on user feedback, then product quality improves, but development cost increases

Engineering Contradiction:

Improveproduct qualityVSAvoiddevelopment cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The system uses simulation models and digital twins to create virtual copies of products for testing design iterations. By performing rapid iterations in the virtual environment rather than physical prototyping, manufacturers can improve product quality through multiple design cycles without proportionally increasing development costs.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The system replaces physical prototyping and testing with computational simulation and data analytics. This substitution of mechanical processes with digital methods enables rapid design iteration while significantly reducing material, manufacturing, and testing costs associated with traditional development cycles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables manufacturers to quickly and interactively resolve product-related issues, reduce time and cost, and provide personalized prototypes, enabling faster market delivery and improved customer satisfaction.

Implementation Method 1

provides for 3D printing, responsive to the modified design solving the problem, a specification of the modified design

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Data Source

PatentUS11300945B2Automated prototype creation based on analytics and 3D printing

Publication Date: 2022.04.12 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

Using an analytical model, a problem related to a product is identified from a collection of report data, the product being a three dimensional (3D) solid having a shape and produced from a manufacturing process. The problem is correlated with a set of factors. The set of factors describes a circumstance in which a user performs an operation of the product. According to a weight assigned to the problem, the problem is selected for prototyping. Using a processor and a memory, the set of factors and the operation are simulated by using a modified design of the product. In response to the modified design solving the problem, a specification of the modified design is provided for 3D printing to the user.