Cesaroni Design: Case Study, Prototyping and Testing

Manufacturing Options & Vendor Sourcing	Vendor sourcing matched the proper manufacturing process and supplier to the new product design. Early involvement with vendors reduced design changes and lead-time. We started sourcing estimates for tooling and piece-part costs from the initial concept geometry as a result of our long-term relationships with suppliers.

Prototype Design	Form refinement continued with the development of the prototype design. Our prototyping process focused on problem-solving design challenges present in the refinements to specific design characteristics. Prototype geometry contained fully defined exterior surfaces with draft, preliminary ribs, bosses and parting line joints. This geometry was built around interior components with clearance checks performed based on the client's specifications. Prototype geometry is a valuable template for the final design, however it is not used directly for production tooling. Our ability to coordinate effectively with the engineers at Böwe Bell+Howell streamlined the quality of the part files.

Prototype Build	A prototype model was built using the prototype geometry to physically represent the new product design. The aesthetics, number of parts, service, industry standards, manufacturing processes, materials and assembly were all represented as accurately as the CNC process permits. Sixteen injection molded ABS plastic parts, welded sheet metal and one polycarbonate control panel overlay were assembled to the mechanical model to ensure fit, finish, assembly and service. Based on our collective efforts, the challenges were overcome and the design was ready for production.