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Product Designing

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In this section we will go through the basic steps of developing plastic products using Top-down design methodology.

The focus of the exercises covered in this section is the good understanding of the top-down design methodology. We will develop the products with the Pro/E tools learned in previous section. Here we will emphasize the top-down design concept and not the tools that Pro/E offers. In this way the reader will develop a strong interest in this design approach and will follow the remaining chapters vigorously. 
   

EXERCISE 1

In this exercise we will create a plastic product consisting of three parts

The topics covered are as follows.

  • Analyzing requirements of the product assembly and deciding what geometry needs to be created in Skeleton model
  • Building Split Surface, the surface where two components of a product join,  when the components join along 3-D surface
  • Considering the manufacturing constraints while creating geometry in skeleton

 

We will see how to achieve the following goals for the shown assembly of components using TDD.

  • Profile of the TOP and BOTTOM parts, forming the housing, should be same and both components join along a 3-D surface
  • Profile of LED COVER and accommodating cut in the TOP part should be same and outer shape of both parts follow a common surface
 
Skeleton Model
Showing geometry that will be shared by multiple components


 
Assembly of Finished Components




Cross-Section of Assembly showing Interlock Details

EXERCISE 2

In this exercise we will create a plastic housing for a remote-control consisting of four parts

The topics covered are as follows.

  • When should a designer define the complete skin of a product in skeleton
  • When should a designer apply drafts and rounds to the geometry in skeleton
  • What geometry should not be created or merged in skeleton
  • Using the surfaces copied from the skeleton model to create solid geometry in components

 

We will see how to achieve the following goals for the shown assembly of components using TDD.

  • Profile of the TOP and BOTTOM parts, forming the housing, should be same and both components join along a 3-D surface
  • The elliptical cut at the front side should be of same size and shape in both parts.
  • Profile of BATTERY COVER and accommodating cut in the BOTTOM part is same and the outer shape of both parts (including underside and side) follow common surfaces
  • The round value is same for both parts



 
 
Skeleton Model
Showing complete skin, split surface and eliptical-cut surface


 
Assembly of Finished Components


Details of Emitter Hole and Elliptical cut



BOTTOM and BATTREY COVER Components



EXERCISE 3

In this exercise we will create a plastic housing for a mobile phone consisting of three parts

The topics covered are as follows.

  • Defining the skin of the product by using advanced surfacing techniques
  • Building the drafts into the surfaces that define the body shape
  • How to implement TDD for products having non-uniform thickness
  • When should a designer define the complete skin of a product in skeleton
  • Using surfacing techniques to hollow out parts having non-uniform thickness .

We will see how to achieve the following goals for the shown assembly of components using TDD.

  • Profile of the TOP and BOTTOM parts, forming the housing, should be same and both components join along a 3-D surface
  • Profile of LCD COVER and accommodating cut in the TOP part is same and outer shape of both parts follow common surface
  • The round surfaces are shared by both (LCD COVER and TOP)
     
 
Incomplete Skeleton Model
Showing side and top surfaces


Assembly of Finished Components


Cross-Section of Assembly


Component with Non-Uniform Thickness

 

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Testimonials

"After going through of your Top-down tutorials, I would like to mention that it is the best material about Pro/Engineer available on the market at this moment. It is evident that information presented is the result of a lot of work and huge experience, which saves users days of working by-self."

Slobodan

Bertrandt AG, Germany

Currently doing Ph.D. in Mechanical Engineering