Pre-Production Prototypes

A Pre-Production Prototype (PPP) approach is an appropriate design/investment strategy for a device with a high probability of going to production. Such machines will typically have well-defined performance, reliability, physical attribute specifications, annual production rates of 20 or more, and a challenging production unit cost target. The PPP effort goes beyond a Technology Demonstrator effort by engineering for full compliance to all specifcation details and including a Design for Manufacturability and Assembly (DFMA) program.  The machine is built using near production component manufacturing methods and the PPP is typically required to pass significant qualification testing requirements. Typically, this involves minimizing the assembly part count, optimizing all significant machine components and minimizing assembly labor content.

Pre-Production Prototype   Military Vehicle Fan In Expeditionary Fighting Vehicle (EFV)
Barber-Nichols Model BNF-01-000 Pre-Production Prototype Fan
in Expeditionary Fighting Vehicle (EFV)

BNI has considerable experience designing products directly as Pre-Production Prototypes using sand casting, stereo lithorgraphy (SLA) based investment castings, or even laser sintered components.  Depending on the aggressiveness of the targets, this approach may be once through or iterative as the individual component designs are traded for manufacturing ease. After successful qualification of the product, and/or system, further savings can then be realized by investment in hard tooling and manufacturing fixtures. All of these steps have been successfully implemented in Pre-Production Prototype efforts for BNI's customers.

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