Working prototypes start with well defined CAD solid models. The prototypes are used for proof of concept, final acceptance, and marketing. A short time to market for a new product is important. Working durable prototypes are invaluable during the acceptance and initial sales phase.
Protomatix integrates many types of discreet sensors, complete systems, and programmable logic controllers to meet clients specified feature set and needs. Including schematic and circuit board design to incorporate discreet sensor and system signals.
Robotics and Automation
Protomatix designs automation and robotic systems. Systems may include vision and sensor input. Motion controllers may drive servo or stepper motor, pneumatic, and hydraulic powered actuators. Off the shelf components and or custom parts may be incorporated into the systems. Cost and effectiveness is key the automation design process.
CAD solid modeling
Using current solid modeling techniques, Protomatix designs and documents parts and assemblies. Solid model files contain attributes such as material, color, configuration, revisions, and other critical information that is used to produce a product.
CAD models help to assure quality documentation and a product that can be manufactured efficiently. A complete bill of materials, assembly documentation, and costs involved are generated from the CAD models.
Schematic capture - Printed Circuit Board Design and Layout
Schematics are created to incorporate electronic product features and to include current component attributes. Time to market and cost are critical concerns when specifying electronic components into a schematic. A bill of materials and a network list is generated from the schematic. The network list information is used in the circuit board design process.
The circuit board design process generates many types of files and documents for the bare circuit board fabrication process, and the circuit board assembly process.
The file generated are:
Gerber files (artwork) for the bare circuit board fabrication process.
SMT paste stencil information (artwork) for fabricating solder paste stencils used in the surface mount component assembly phase of the circuit board assembly process.
SMT component location (XYZ) information used in the pick and place assembly phase of the circuit board assembly process.
A selective flow solder pallet design for use in the through hole component soldering phase of the circuit board assembly process.
Manufacturing documentation used in all phases of bare circuit board fabrication and circuit board assembly process.
Silicone RTV - Polyurethane injection molding and tooling
Parts intended for "hard tooling" (steel, hardened steel) ABS injection molding can be prototyped using "soft tooling" (metal such as aluminum) injected with polyurethane. Soft tooling and molds produce dimensionally accurate parts. Flexible tooling (silicone RTV) molds allow for faster turn times and parts with slight overhanging features.
Protomatix designs and fabricates soft tooling molds and flexible silicone RTV molds and tooling for urethane casting or injection molding.
Polyurethane parts may be sanded, machined, and painted. Finished parts may be used for proof of concept, prototype acceptance, and low volume preproduction builds.
Protomatix designs many types of mechanical, electronic, automated testing and assembly fixturing.
Custom fixture types include:
Dedicated electronic test fixtures
Functional test fixtures
Final acceptance test
Mechanical precision measurement fixtures
Fixtures are fabricated to clients specified feature set and needs. Including integration to existing or new systems. Fixtures may be manual, simiautomatic, or programmable.
Protomatix designs labels and fabricates durable paper or plastic laminate short run labels and appliques for prototypes and first run products requiring user and interface labels. Assuring a quality fit label, for good look and feel.
Graphic animations may be created using CAD solid models. These animations can be used for proof of concept, operational verification, and sales. We render our still and motion graphics to give photo realistic qualities to the images. These prints or files can be used directly for copy ready art or web publication.
Reverse Engineering, Reengineering
Old parts may need to be updated to interface with current designs. Protomatix can mechanically scale a part with precision tolerance. The point cloud generated from the precision measurements can be used to recreate a solid model. Redesign can be done easily after the solid model has been created.
Design for manufacturability (DFM) and design for test (DFT) are an important steps when designing new products. The design must flow through the manufacturing process easily to keep associated costs low. Protomatix can give guidance to our clients to assure a quality product with minimum time to market.
Materials requisition planning is a part of manufacture engineering. This process assures outside vendors are capable of delivering components and sub-assemblies in a timely manner.
Protomatix keeps track of the product design and assembly issues. Our goal is to not let the product slow down in the manufacturing process.
After the first prototype or run of the product refinement may be required. Product design and development are often iterative processes. All parties involved need to express their concerns and make suggestions for improvement. Protomatix works with our clients to achieve the most cost effective improvements.