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Prototyping Services

Contact DTB about the possibilities of prototyping for your product.

Dayton T. Brown’s 300,000 sq ft engineering and test facility accommodates all phases of product development, effectively and efficiently.

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Design, Test, Evaluate — Prototyping

Prototyping can be an important part of product design, allowing our engineers to develop and test improvements to existing designs or in creating new products. In some cases, a series of prototypes will be designed, constructed and tested. This, in turn, refines the design before it is put into production.

Because DTB is an engineering and test facility, it provides us with a great advantage when it comes to research and development, prototyping and product design.

The outcome of testing a wide variety of products gives us insight to what kinds of components work in all kinds of conditions and in all types of environments. This gained knowledge, is then applied and incorporated into the development of the prototypes that DTB is involved with. This in turn has historically provided DTB and its customers with prototypes that are more successful in a shorter amount of time, while automatically incurring less cost in the developmental phase.

Step Through Our Prototyping Process
  • For a particular industry sector, a market study is performed to evaluate a problem or need for a certain product or a customer would submit a set of design requirements for a product they need to be produced
  • Alternate solutions are developed that meets the requirements to solve a particular problem or need of a product.
  • A down selection is made of the alternate solutions for the best fit approach.
  • A virtual electronic model is developed through the aid of computer software programs that applies to the type of engineering application at hand.
    • In the areas of structural/mechanical applications, a few computer software programs that might be used would be 3D cad design systems, such as Catia, Autodesk Inventor, Solidworks and Ansys.
    • For electronic applications, AutoCAD Electrical computer software might be used or in fluid flow and thermodynamics applications it could be CF design software
  • Once a virtual electronic model has been developed, a rapid prototype would be produced by using solid freeform techniques such as Stereo Lithography or Fusion Deposition Modeling. Through the use of these processes, a rapid prototype model can be made from many different types of materials, depending on its application. The material chosen could be what the final product would be made from.
  • After a full review of the rapid prototype, a full scale prototype would be fabricated and now be evaluated for its form, fit and function in the application used. During this evaluation phase of the project, the prototype would go through some preliminary testing which would be used to uncover flaws or imperfections and may be revised and/or modified to improve on its overall performance in achieving its design expectations
  • Once the prototype has been optimized, the final drawings are revised and a first set of articles are fabricated. Depending on the new product being designed, castings, molds, assembly fixtures and tooling might be required in order to fabricate the first set of production articles. These first articles would then go through its required testing in order to meet the specifications for those particular industries standards


Example Projects

The following are examples of products developed at DTB. PrototypingEA-6B Exhaust Tail Pipe Assembly An assembly which is attached to the twin jet engines on the EA-6B aircraft that guides the flow of engine exhaust to the rear of the aircraft. The next illustrations show the 3D solid model of the tail pipe assembly and the prototypes that were fabricated.

prototype-example-ladderT-45 Aircraft Boarding Ladder An assembly which is temporarily mounted to the side of a T-45 aircraft so that the pilot and co-pilot can climb into the cockpit. The ladder is made up of an ultra-light weight all aluminum welded construction with a corrosion resistant coating and rubber pads that provide a protective interface with the aircraft. The next illustrations show the 3D solid model of the T-45 Aircraft Boarding Ladder and the prototype that was fabricated.

prototype-example-fuel-cellFuel Cell Container A container to store and transport military fighter aircraft fuel cells. The fuel cells were basically rubber bladders that could not stand up under their own weight. Therefore, these containers were required to suspend or hang the fuel cells so that they would not collapse or fold down on themselves. The next illustrations show the 3D solid model of a prototype sample of a fuel cell container assembly and the first article that was fabricated.

Navy Prototyping

DTB has the facilities, personnel and partnerships in place to support Prototype Development. Many times, Prototype Development crosses over and is a sub component of a larger program in the realm of Value Engineering, Reverse Engineering, Product Enhancement, Cost Reduction, Life Extension, Diminishing Aircraft Parts and Manufacturers.

DTB has the expertise and suppliers capable of designing and fabricating precision parts for multiple applications within the land base, shipboard and aerospace communities.

Examples of these include the fabrication of EA-6B tail pipes and E-2C hydraulic actuators. Land base equipment includes ejection seat and aircraft wing dollies.

Prototype Design

At Dayton T. Brown we have designed, developed and fielded specialized test equipment for both the military and commercial markets.

Our core design competencies reside in the development of hydraulic and pneumatic test systems as well as electronic and electromechanical systems.

Rapid Prototyping

As part of our Design Engineering Services, DTB can provide rapid prototyping of 3D CAD Solid Models using solid free-form fabrication techniques such as Stereo Lithography or Fusion Deposition Modeling (FDM) from a network of qualified suppliers.

These processes take 3D CAD Solid Models to physically prototype the part using a variety of materials.

Rapid prototyping is an excellent tool which can be used to stream line the overall design/product development process to achieve a shorter time to market.

Turnkey Design and Fabrication Services

What is unique about the Lab Div. at DTB and valuable to our customers, is we consider ourselves to be a “One Stop Shop” company. When it comes to reverse engineering and prototype development, DTB has the unique capability to design, fabricate and test both new and redesigned existing products.