Prototype Build Using Augmented Reality

Case Study

Challenge

Build multiple vehicle frame prototypes, each consisting of more than 300 components. An evolving product design challenged our ability to complete geometry fixtures traditionally used for positioning and welding components. Our customer still required the prototypes to be delivered to the original timeline. It was clear that we needed an innovative solution.

Solution

Our research and development team determined that augmented reality, using the Microsoft HoloLens and Theorem XR software, was the right solution.

Physical parts were positioned and aligned to match the holographic 3D model and held in place using manual clamps.

Aligning virtual and physical prototypes is a complex process that requires significant training and hands-on experience. The process includes cleaning workspace surfaces, clamping base components down, aligning and scaling the virtual model to its corresponding physical part, positioning parts, and tack welding. These procedures were repeated until all sub-assemblies were built. Alignment checks at every step of the process were critical to overall build quality — the HoloLens made this process very efficient.

Virtual weld and sealant locations were included in the 3D model and marked onto the physical parts using the HoloLens. The ability to see the virtual sealant width and thickness through multiple layers of materials provided a unique perspective. We identified build sequencing and tool access challenges and quickly made optimizations.

After final alignment checks, sub-assemblies were joined together through spot welding, gas metal arc welding, and fastening to form the completed frame. Weld points were marked with ‘tolerance spheres’ in the virtual model, providing visual confirmation of accurate placement.

Result

The team successfully delivered accurate prototypes on time, while developing a new process that leveraged the power of augmented reality.