Collaboration Key to 3D Success
In the early 1990s, MIT graduate student Thomas Massie, along with Kenneth Salisbury, then a principal research scientist at MIT's Artificial Intelligence Laboratory, developed a haptic device for touching 3D computer data as Massie's thesis project. The device, named Phantom, achieved wide recognition at MIT and within the wider research community for its ability to "touch" and manipulate virtual objects on a computer screen.
In 1993, Massie founded Sensible
Technologies, Inc. (Woburn, MA) to build and market the Phantom
Desktop, shipping the first unit the same year. Next, the Phantom
Desktop unit was designed, based on high-volume production processes,
in anticipation of wide acceptance of SensAble's FreeForm Modeling
system-a unique 3D touch-enabled computer-aided sculpting system that
allows users to rapidly produce highly detailed organic models. But the
company was just five years old, available project capital was limited,
and exact production volume-which was dependent on market acceptance of
the new product design-was still uncertain.The Road to Success
In 1998, after talking with a local die caster, SensAble approached
Armstrong Mold Corporation (East Syracuse, NY). Armstrong specialized
in development applications and had decades of experience producing
functional prototype and short-run components in metal and plastics. As
a first step, Armstrong engineers facilitated a first-round design
application review for the three critical new components of the Phantom
Desktop-base, front cover, and back cover. DFM (design for
manufacturability) guidance was provided to avoid production problems.
Armstrong's rubber plaster mold (RPM) process was used to make the
three components as aluminum castings. RPM provides castings with the
appearance and properties of die-castings, but tooling costs are lower
by an order of magnitude, and lead-time is only two weeks, as opposed
to two to three months. SensAble placed an order for prototypes, and
provided CAD files for Armstrong Mold to use to produce
stereolithographic models to develop the silicone rubber patterns used
in the plaster mold foundry. Within three weeks-at minimal cost-a
prototype Phantom Desktop device was assembled, fully functional, and
ready to present to the design community. It had not been necessary to
compromise the "look and feel" of the design in any way.
"The FreeForm system was an instant success, and was increasingly well
received in the marketplace," said Tom Massie, president of SensAble
Techno-logies. "Armstrong Mold continued to produce small-lot casting
orders to meet the required assembly rate without delays, and with no
need to hold large parts inventories. As the volume of orders
increased, Armstrong engineers suggested converting the two cover
castings to their graphite permanent mold process. When we did this, it
provided a higher production rate and a reduced piece price, but still
with only a modest investment in tooling." Further Market Growth
SensAble saw further market growth in their future, so in early 2003
Armstrong Mold hosted a one-day cost reduction initiative meeting at
their plant to plan for the unfolding product development path. As a
result, cost reduction modifications to the RPM tooling were introduced
as an interim measure, and plans were made to migrate the two covers to
other manufacturing processes. The front cover was converted to
Armstrong's short-run die-casting process, while the back cover was
produced by the kirksite plastic injection molding process. Further
growth in production rates will be achieved when needed by substituting
regular production die-castings and injection-molded parts. It will not
be necessary to change the appearance or function of the assembled
Phantom Desktop device.
"Introducing a new product to market involves making early decisions
that critically affect the success of the whole project," says Paul
Armstrong, Director of Sales and Marketing of Armstrong Mold.
"Sophisticated industrial design and strong styling are important to
communicate product credibility-in the marketplace, and possibly also
to investors. Thus, prototypes should look and function like the final
product. Investing up-front in production tooling-such as steel
dies-involves a major commitment of capital and lead-time before a
single part can be produced; simulating a mass-produced product with a
short-run process is usually a much better option."
The apparent piece/price advantage of the high-production process only
occurs as a function of large production runs, and is offset by the
cost of holding large inventories. An additional advantage of the
short-run processes is that design changes can be made rapidly and
inexpensively should they be required based on experience or feedback
from the marketplace.
For product and corporate information for Armstrong Mold (East Syracuse, NY), visit their Web site at www.armstrongmold.com. For SensAble Technologies, Inc. product and corporate information, visit www.sensable.com.
