**2.1 Non-functional models**

Referring to **Figure 4**, it is during stages 3 and 4 that physical models play a very important part in industrial design. During Stage 2, designers rely on sketching as an ideation tool. Traditionally, it was common (and still is) to produce concept sketches using pencil/ball pen/felt tip pen on paper generation concepts in freehand perspectives. While perspective drawings convey the form and shape of the product being conceptualised, not all people can interpret the sketches and understand the nuances of the design concept being represented in those sketches.

For that reason, industrial designers resort to fabricating study models in foam, clay, plaster or any other material to supplement the concept sketches (**Figure 5**). Many a times these study models are made in full scale for the client and/or potential users to get a feel of the size, form and fit as well as the design details.

When products such as a car is being designed, study models take on a new meaning. It is a common practice to sculpt full scale models of the exterior using clay. This allows for not only verification of the form and the subtle carvings on the surface, it also allows for making changes to these surface curves and details which can then be captured back into detail design. **Figure 6** shows the clay modelling facility of a car manufacturer.

According to the Modelling Manager at Ford,<sup>2</sup> a full-size clay model of a vehicle allows the designers and engineers to spot potential issues in both the interior and exterior of the vehicle which are not apparent on digital or small-scale models. With the advance reverse engineering technology available designers model the changes that necessary by hand and scan those changes back into the computer in order to capture it and integrate this into the main 3D data to integrate into the final design.

<sup>2</sup> https://social.ford.com/en\_US/story/ford-community/automotive-news/we-reveal-a-ford-automotivedesign-secret.html

*Rapid Physical Models: A New Phase in Industrial Design DOI: http://dx.doi.org/10.5772/intechopen.88788*

#### **Figure 6.**

*Design and Manufacturing*

**2.1 Non-functional models**

**Figure 5.**

**Figure 4.**

*Industrial design process.*

facility of a car manufacturer.

According to the Modelling Manager at Ford,<sup>2</sup>

Referring to **Figure 4**, it is during stages 3 and 4 that physical models play a very

*Study models (source: http://whiteboardps.com/index.php/fwp\_portfolio/acco-swingline-gbc-fusion-laminators/).*

For that reason, industrial designers resort to fabricating study models in foam, clay, plaster or any other material to supplement the concept sketches (**Figure 5**). Many a times these study models are made in full scale for the client and/or poten-

a full-size clay model of a vehicle

When products such as a car is being designed, study models take on a new meaning. It is a common practice to sculpt full scale models of the exterior using clay. This allows for not only verification of the form and the subtle carvings on the surface, it also allows for making changes to these surface curves and details which can then be captured back into detail design. **Figure 6** shows the clay modelling

allows the designers and engineers to spot potential issues in both the interior and exterior of the vehicle which are not apparent on digital or small-scale models. With the advance reverse engineering technology available designers model the changes that necessary by hand and scan those changes back into the computer in order to capture it and integrate this into the main 3D data to integrate into the final

<sup>2</sup> https://social.ford.com/en\_US/story/ford-community/automotive-news/we-reveal-a-ford-automotive-

important part in industrial design. During Stage 2, designers rely on sketching as an ideation tool. Traditionally, it was common (and still is) to produce concept sketches using pencil/ball pen/felt tip pen on paper generation concepts in freehand perspectives. While perspective drawings convey the form and shape of the product being conceptualised, not all people can interpret the sketches and understand the

nuances of the design concept being represented in those sketches.

tial users to get a feel of the size, form and fit as well as the design details.

**128**

design.

design-secret.html

*Clay modelling in full scale (source: https://i.pinimg.com/originals/40/fa/22/40fa22a8d8120cceed06deeb030 2db12.jpg).*

#### **Figure 7.** *Full scale mock up model.*

**Figure 8.** *Mock up model of electric scooter (source: https://www.designideas.pics/porter/).*

During Stage 4 of the design process shown in **Figure 4**, many times, full scale appearance model is presented to the client/audience which shows the exterior details in full including colour, texture and graphics as seen in **Figure 7**. It is a common practice to present more than one concept, hence more than one full scale mock up models are presented. In the case of vehicle/car design, scale models are presented as shown in **Figure 8**.

**Figure 9.** *Foam models to check form and ergonomic fits (source: https://www.pinterest.com/pin/289497082275373127/).*

**Figure 10.** *Low fidelity mock up (source: https://engineeringproductdesign.com/).*

Physical models in industrial design play a bigger role in design decision making than just iterating design/aesthetic variations including partially checking the function and fit of the product being designed.

### **2.2 Semi-functional models**

At the early stages of the design process (Stage 2 in **Figure 4**), physical models play an important role in ascertaining human factors/ergonomics aspects of the product, besides presenting the form and fit. An example is shown in **Figure 9** where the ergonomics of a hand held power tool is important to the success of the product. Variations in the hand hold areas allow potential users to test/play act and give feedback on the right design for such areas.

In designing products with electronic displays and interface, it is a common practice to embed such components into the full scale mock-ups, many a times with

**131**

*Rapid Physical Models: A New Phase in Industrial Design*

rudimentary connections, to enable users to test the first level comfort in user experience. Such a mock up model as shown in **Figure 10** is also termed as' low fidelity' mock up in the industry. A low fidelity mock up allows the design team to verify the functional concept by allowing users to 'playact' the way they probably will use the real product. Designers can quickly make changes to the model based on feedback and make modifications. The almost real-time iteration of the design, allowing for variations in functionality make low-fidelity models an important part of industrial

Furniture designers use quick physical models to verify the concept in terms of aesthetics, manufacturing process and human fits. Such a quick model made by a

Physical models in product development in general, and industrial design in specific, may be classified in several ways. It is best to understand these classifications in order to understand the impact of digitalization and rapid model making

Broek et al. [3] classify and exactly describe physical models according to usage

1.*Visualisation*: models are used for presentations and shape (details). They can support reasoning about shape geometry, curvature and accuracy, texture, colour, finishing, and graphics. Shapes become tangible, local curvature and

2.*Functionality testing*: depending on the tested functions, the model representation is not too precise at those regions where no testing is performed. However, the degrees of freedom for optimal testing must be guaranteed, and testing regions, e.g., ergonomic verification, must be represented accurately.

3.*Physical testing*: a materialised model must be fabricated consisting of the same material of the final product. Accuracy and exclusion of strength variations

related to the fabrication technology are important issues.

*DOI: http://dx.doi.org/10.5772/intechopen.88788*

design in the age of interaction design.

**3. Classifying physical models**

has on industrial design.

and type as:

**Figure 11.**

*Quick furniture model.*

student of furniture design is shown in **Figure 11**.

product appearance can be judged.

*Rapid Physical Models: A New Phase in Industrial Design DOI: http://dx.doi.org/10.5772/intechopen.88788*

**Figure 11.** *Quick furniture model.*

*Design and Manufacturing*

**130**

**Figure 9.**

**Figure 10.**

Physical models in industrial design play a bigger role in design decision making than just iterating design/aesthetic variations including partially checking the func-

*Foam models to check form and ergonomic fits (source: https://www.pinterest.com/pin/289497082275373127/).*

At the early stages of the design process (Stage 2 in **Figure 4**), physical models play an important role in ascertaining human factors/ergonomics aspects of the product, besides presenting the form and fit. An example is shown in **Figure 9** where the ergonomics of a hand held power tool is important to the success of the product. Variations in the hand hold areas allow potential users to test/play act and

In designing products with electronic displays and interface, it is a common practice to embed such components into the full scale mock-ups, many a times with

tion and fit of the product being designed.

*Low fidelity mock up (source: https://engineeringproductdesign.com/).*

give feedback on the right design for such areas.

**2.2 Semi-functional models**

rudimentary connections, to enable users to test the first level comfort in user experience. Such a mock up model as shown in **Figure 10** is also termed as' low fidelity' mock up in the industry. A low fidelity mock up allows the design team to verify the functional concept by allowing users to 'playact' the way they probably will use the real product. Designers can quickly make changes to the model based on feedback and make modifications. The almost real-time iteration of the design, allowing for variations in functionality make low-fidelity models an important part of industrial design in the age of interaction design.

Furniture designers use quick physical models to verify the concept in terms of aesthetics, manufacturing process and human fits. Such a quick model made by a student of furniture design is shown in **Figure 11**.
