Boy, is your head swimming like mine?
It's hard to keep up. Some of the stuff they're talking about is unbelievable.
For instance, they're talking about easy to use $300 toaster-like appliances
to access the World Wide Web (the Internet), they're talking about the
Intel Pentium Pro chip that offers built-in Virtual Reality Modeling Language
(VRML) and hardware processing for creating virtual 3D worlds, they're
talking about CAD programs that make computer models look more realistic
than real life for under $500, they're talking about Microsoft offering
built-in Hyper Text Markup Language (HTML) in the operating system, and
they're talking about machines that digitize parts in 3 dimensions out
of liquid!
It's true. We are living in amazing
times, a renaissance, you might say. This is especially true for product
designers. Product designers are those guys and gals that draw on both
artistic and engineering skills to blend creative and clever insight with
a product's core technology to produce a design that not only does what
it is advertised to do, but looks and feels great to use. I should know.
I work at Teague Associates, a product
design firm that's designed more products for more years than anyone else
in the world. In a competitive market, a product's industrial design might
be the only thing that makes the difference between winning and losing
market share.
Special Challenges for Product Designers
Unfortunately, CAD has always presented
Product Designers with a multitude of compromises. Until recently, most
PC CAD systems only worked well in 2 dimensions. If they worked in 3 dimensions,
you were pretty much limited to a system that would only handle basic rectilinear
and straight circular type designs well, not much of anything else. Product
designers don't work in a world like that. They work in the "real"
world, a world that is full of swoopy organic shapes, a world that requires
designs to accommodate part draft (a tapered wall on a part is used to
allow easy part removal from a mold) and common wall thickness throughout.
We can all look around, right now, and find a VCR, a lawn sprinkler, a
cellular phone, or a lawn chair that was designed with only a handful of
straight lines.
Product designers are a creative bunch. They like to "think outside of the box." They don't like to be hamstrung by rigid rectilinear thinking, or following someone else's design rules. It is well known that the best design work comes from freeform serendipity. At Teague I constantly see design being formed and evolved from "paper doll" cutouts, hand sculptured Styrofoam, bandsawed plastic boat seats, and of course, pencil sketches. Product design requires lots of iteration and true flexibility.
Unlike many firms, Teague invests heavily
in many CAD systems. Our diverse client base makes it absolutely necessary
to stay on top of the different players in CAD technology and be able to
be effective in many different CAD environments. As a result, we have a
very solid base for understanding the
differences
between the systems and how best to utilize their strengths. If a CAD system
is to be truly successful in this type of environment, there needs to be
a strong focus on the Graphical User Interface (GUI). CAD systems of the
future will need to capture design intent and accurately document "vision"
without getting in the way of the designer or the design process.
There are lots of products on the way
to help in this endeavor, both hardware and software. On the hardware side
we have: virtual reality headgear; touch sensitive digitizing tablets;
super fast, stereo hardware rendering graphics cards; high resolution imaging
systems; Spaceball-syle pointing devices, and 3 dimensional "plotting"
devices and machines. On the software end we have: high-end parametric
and variational geometry solid modelers; low cost ACIS solid modelers that
allow the user to work with fully shaded models in perspective mode; GUI's
that are getting very friendly; and integrated document control managers
that allow project workgroups to exist across international borders via
the Internet.
This article will discuss some of the
software trends. A follow-up article will discuss hardware trends in the
product development arena.
How different CAD vendors are addressing the
needs of Product Designers
Alias/Wavefront's Alias
A phenomenal piece of software, Alias
has succeeded better than any other software package in pushing the user
environment towards freeform organic shapes. Alias is an extremely powerful
NURBS surface modeler that has an unprecedented, easy to use GUI. Their
rendering and visualization capabilities are the best in the world. The
photorealism is so real that Hollywood makes extensive use of Alias for
computer animated special effects. Alias rendering capabilities are demonstrated
in Jurassic Park, Species, Terminator, and countless other movies. (So
real they made me jump out of my seat.) The programmers at Alias are continuing
to push the software toward the creative end of CAD. Such software is being
utilized extensively by industrial designers and is better known as CAID
(Computer Aided Industrial Design) software.
Adding
new capabilities, the programmers created a sketcher that allows the designer
to use a pressure sensitive stylus to sketch-out 3D, volumetric sketches.
This is far closer to the way industrial designers think than, say, parametric
feature modeling. The concern with CAID software is not functional validity,
but more along the lines of the way something looks, how light dances off
the object, and how well texture mapping works. That's one of the reasons
Alias is also a favorite software for game manufacturers. I suspect that
right now, for the Internet, numerous virtual worlds are being created
with this software.
Although Alias is not an engineering
software and may not provide adequate data for part function validation,
many industrial designers are using the software to skip the engineering
process altogether and go straight to tooling and prototypes. Although
conventional wisdom may speak otherwise, this technique can be used very
successfully, depending on the product being designed. If the product is
very simple and the principles well understood, the technique can work
very well. If the product is complicated, or requires serious analysis
to be understood, it may not be such a good idea. The decision to skip
an engineering phase is not a trivial one and needs to be made on a case
by case basis. At any rate, Alias has a powerful presence in the product
development arena, and will continue to do so, even at a retail price in
the neighborhood of greater than $20,000.
SDRC I-DEAS Master Series
SDRC
is a company that has been around for quite a while. I remember seeing
ads for SDRC, years ago, when I was still going to school learning to be
an engineer. Back then, they were doing engineering analysis, not much
else. Even their name implies this, Structural Dynamics Research Corporation.
However, they've successfully redefined themselves. They are now a well
respected CAD software provider in a very competitive market. So respected,
in fact, that they have just closed a multimillion dollar deal with Ford
Motor Company to become Ford's CAD system of choice. Why? Lots of reasons.
Some of the reasoning lies in their success at utilizing tight integration
of their modules while still providing "best of class" software
products (in their modules) for their users. Their 3D CAD system uses a
variational geometry engine to define 3D models. Without forcing a model
to be fully constrained, a variational geometry engine provides the ability
to drive geometry with parametric constraints and dimensions. SDRC also
provides a highly interactive 2D drawing interface called Dynamic Navigator.
The Dynamic Navigator recognizes assemblies, parts, edges, surfaces, entity
geometry, and all constraints to provide continual visual feedback to the
user, based on cursor position alone. This type of feedback is similar
to the type of feedback one gets from Vellum, a 2D drawing package that
was originally written for the Apple Macintosh. I-DEAS finite element analysis
and dynamic analysis packages are tightly integrated with the modeler,
surfacer, and shader, not to mention project management and others, to
give the sense of working in a seamless environment. The depth of functionality
is what one would expect from a high-end CAD system.
Unique
to I-DEAS, each module communicates to the other using the standard UNIX
email system. I found this to be one of the most amazing uses of the standard
UNIX system I've ever heard of in a CAD environment. Basically, each module
sends the other modules "email" to notify each other of updates!
Then a simple click of a single icon is all that is required to update
any history supported application. This means concurrent engineering and
development of a product could span continents. SDRC plans on implementing
a Win/NT version real soon that will use MSMAIL.
The SDRC I-DEAS user interface is excellent
and provides the designer with the ability to get feedback on "what
if" scenarios very quickly. Unfortunately, their renderer's photorealism
is not as good as either CDRS or Alias, but it is plenty good for communicating
internally. At around $25,000, this product competes head to head with
Pro/Engineer.
Autodesk's Mechanical Desktop
Although still missing some key functionality,
Autodesk's new Mechanical Desktop
is really worth a look. Mechanical Desktop is basically an updated AutoCAD
Designer and updated AutoSurf that are "seemlessly" integrated
together to provided unprecedented functionality in an AutoCAD interface.
New functionality includes the ability to "cut" AutoSurf surfaces
into an AutoCAD Designer solid model, and an assembly modeler to allow
parts from different files to be joined together parametrically. What's
still missing is the ability to provide multi-face shelling of a part (a
hollowed-out solid), and part draft based on a parting line as opposed
to a drafted surface based on the feature created. AutoCAD users will appreciate
this added functionality within a feature rich AutoCAD environment, of
which hundreds of thousands of users are accustom.
The new Designer appears to be very
robust, provides ANSI and ISO representations of threaded fasteners, and
can import and export ACIS solids models. Autodesk has done very well with
this offering, but in my opinion, still falls short of a true product design
development environment. I feel it is absolutely necessary to provide automatic
shelling of parts and parting line draft applied to the finished part,
not just the features. Also, iteration is very important in a product development
environment, and although it is possible to "redefine" certain
aspects of a Profile, it is not possible to add or take away entities.
This can be a drawback, because if the user has changed his mind about
a Profile, all of the "children" downstream in the history of
the part might get lost. Visual feedback is another area that could use
some improvement. Many of the current CAD programs, like Trispectives,
SolidWORKS, and Alias, allow users to work directly on a shaded model in
perspective mode. This is great for visualization, and eliminates ambiguity
during the design process.
Parametric Technology's Pro/Engineer
Pro/Engineer is the granddaddy of all
parametric modelers. Parametric Technology
practically invented this style of designing in 3D solids. I can remember
back when I was demonstrating AutoCAD version 1.4 to a friend, and he asked
if AutoCAD could "synthesize." The science was so new at the
time that the term "parametric," as applied to CAD systems, hadn't
even been given a proper name yet.
Today Pro/Engineer's following has
grown considerably. Their product is excellent, and it addresses many downstream
needs of engineers, tooling vendors, analysis, document control, sheetmetal
vendors, and cable routers. Now, with their acquisition of CDRS, industrial
designers will be able to work in a rich modeling medium that will be transferable
and supported by Pro/Engineer. Their product offerings go way beyond mere
parametric modeling. They have created a tightly integrated environment
from which to do design, and analysis, and provide dependable manufacturing
data. Pro/Engineer can provide solid models that some of the other systems
just can't. However, you pay for it.
Like any of the other high-end CAD
systems (i.e., I-DEAS, Alias), Pro/Engineer is expensive, around $20,000
for a truly functional system. However, PTC does offer Pro/Jr for around
$4,000 if you don't mind the limited functionality it provides. Personally,
I find the system extremely hard to learn. I feel this is a direct result
of the User Interface. Pro/Engineer requires that the user travel deep
into the menu structure to reach commonly needed visualization commands
like SPIN and ZOOM. Please note though, that annoying issues like these
can be taken care of as they arise through the use of Map Keys, a macro
functionality. I hear that the interface is getting better (more graphical)
with release 16, but it normally takes between 500 to 1000 hours for a
user to make serious, productive use of the system. As a result, training
is expensive, in terms of lost time. Knowing this, companies will often
pay experienced Pro/Engineer operators (more than 1000 hours experience)
more than anyone else in their department, just to get work done. These
aren't problems if you are making lots of money using Pro/Engineer, but
can seriously hamper your financial condition if you aren't.
In spite of the learning curve, Pro/Engineer
is an amazingly successful product. They have provided the industry with
a robust modeler that can do just about anything. As a result, they have
produced a loyal following.
SolidWORKS
Here's a company that is going to cause
Autodesk a lot of grief. They were founded by a bunch of folks that helped
start Parametric Technology, but left to start SolidWORKS.
They created a really great product that I would consider that it could've
been the next generation Pro/Engineer, if Pro/Engineer were to be re-written
from the ground up to be more user friendly.
One unique characteristic of SolidWORKS
is that it was written specifically for Win95. Of course, it can also be
used under Win/NT. Models can be operated on in shaded mode, but perspective
is not yet implemented. One nice feature that SolidWORKS uses is a directory
tree like window to graphically show the order of feature creation. This
directory tree allows the user to reorder the feature creation by simply
dragging and dropping feature "children" and "parents"
into any position of on the tree. SolidWORKS also allows variational style
modeling, that is to say that the user will not have to fully constrain
the model in order to get results since the software will make numerous
assumptions about the model based on "self-evident" relationships.
In addition to the standard things one would expect from a world-class
modeler, like muti-face shelling and drafting of surfaces, users are able
to use features from one part, like borrowing a complicated cutout from
one part and simply dragging it to another part.
Overall, the 3D modeler appears to
be very clean, convenient and intuitive. SolidWORKS seems to have done
an equally impressive job with the 2D drawing generator. The package provides
appropriate thread representations, hidden-line removal, centerline placements,
cut-section views, text annotations, and adherence to ANSI and ISO standards.
They've done their homework, and it shows.
The package is adequate for most design
work, and can do very complicated filleting and blending of surface intersections.
Basically, the package falls short in maturity. It is a new offering and
as a result, it does not have any sophisticated surfacing capabilities
(other than a great blend function), or total support for the migrating
CAD user (i.e., limited data translation, cannot read or write out ACIS
or DWG files). However at around $4,000, it will make a lot of inroads
into the market, and cause quite a stir.
3D/Eye's Trispectives Professional
Although not ready for professional
product design use, Trispectives Professional is in many ways a favorite
of mine. 3D/Eye just may drive the CAD
market into the next millennium more than any of the other packages. I
see real potential. Their vision is to have "3D on everyone's desktop."
Trispectives provides one of the most powerful ACIS modelers and raytraced
rendering packages available on the market, yet makes the interface extremely
easy to learn and use. Using a technique called SmartRender," a user
is encouraged to work on a model in shaded perspective mode with phenomenal,
breathtaking results. Modeling is done using a Visio-like approach of dragging
and dropping parametrically driven "Intellishapes" from a side
"catalog" onto a base part. Assembly is handled using coordinate
"Attachment Points." A person can actually become productive
on Trispectives in only a couple of days. The product is amazing yet costs
less than $500, works under Win95 and Win/NT, and is being offered to the
general public through standard retail outlets like Egghead and college
bookstores. Trispectives is such a threat to AutoCAD, that Autodesk has
issued a list of "counter comments" to their dealer network to
counter customer comments about the package. Personally, I believe this
product is a threat to all CAD programs as we know them, especially if
3D/Eye can sustain profitability.
One thing that is often overlooked
when reviewing Trispectives Professional is the fact that it is not only
a great 3D solid modeling package, but it features an extremely powerful
data translator, too. Through their Import/Export options, Trispectives
can translate just about any kind of 2D data into just about any other
kind of 2D data (e.g., TIFF, GIF, BMP, JPEG, EPS, PCX, TGA, RTL), and 3D
data into many other types of 3D data (i.e., 3DS, Visual Basic, VRML, DXF,
STEP, SLT, Trimmed IGES, and 3 different versions of ACIS). Data translators
that don't have this much capability are being sold to companies for $2,000
or more, and they don't do anything else. Trispectives translates ACIS
models so well, that using Trispectives as a front end to programs like
AutoCAD is a natural.
Some side thoughts about the future of CAD
systems in general
Currently, high-end CAD systems like
Alias, Pro/Engineer, and I-DEAS are expensive, both in original purchase
price and in maintenance. For a basic useable product, software runs in
the neighborhood of around $20,000. Currently, good hardware runs around
the same price. Software maintenance agreements that provide a couple of
updates and phone support run around $2,000 per seat per year. Be sure
to read the fine print of your licensing agreement before you commit. Chances
are you may never be able to resale your copy of the software. Not only
is the software and hardware expensive, but it is relatively scarce, when
compared to low-end CAD seat. As a result the resource pool from which
to draw skilled labor is smaller than from the resource pool stemming from
the low-end CAD market.
I am very happy to see that serious
CAD functionality is starting to develop in the low-end CAD market, and
that there is going to be a big shakeout soon. Therefore, it may be in
your best interest to determine whether or not you will be able to make
a satisfactory, long-term return on investment with a high-end CAD system,
before you get stuck with the tradeoffs for life.
So what's in the future of CAD for Product
Design?
Looking at the above, we can see a
trend toward lower cost variational geometry modeling, a more user friendly
environment, and an environment that allows the user to work on a ray-traced
shaded, texture mapped model while remaining in perspective mode. This
is good news for product designers. The future will allow product designers
to make their mistakes quicker, in a more realistic environment, where
visual feedback is important.
On the high end, I think users will
continue to pay considerable money for programs that go beyond simple 3D
CAD design, and integrate business need solutions such as project management,
analysis, photorealism, interconnectivity to databases, JIT (Just In Time)
manufacturing, concurrent global engineering, and so on. However, it is
good to note that many of the low-end CAD solutions are providing considerable
functionality for the money and may be adequate for many product development
applications.
In any event, the CAD system's GUI
will need to provide the shortest distance between man and machine. Some
CAD systems do this very well in 2D. Some, like I-DEAS do it very well
in 3D. Some programs are gaining ground on ease of use, like Trispectives,
and some programs like AutoCAD and Pro/E are so full featured and have
so much associated baggage to carry along, that they would do well to pursue
a complete re-write and/or provide a shift in user interface. Autodesk
has actually gone through a complete re-write with release 13, and has
become more "object" oriented, but they are still learning how
to package product functionality for the end user. The net result is that
product designers are living in exciting times and the current trend in
CAD will result in better products us all.
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Michelle Pillers, P.E. is a licensed, practicing mechanical engineer and former Director of Product Development for Walter Dorwin Teague Associates, Inc. As an avid user of AutoCAD's solids modeling packages, she can be often found helping users on CompuServe's AutoCAD Forum. Michelle can be reached via email at mpillers@edeinc.com. Be sure to visit Michelle's new business venture's website - Evolution Design Engineering - at http://www.cyberspace.com/~mpillers/evolution-hm.html.
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