Rapid Prototyping as a Product Development Tool : A Case Study on the Development of a Drone Deployment Mechanism

This thesis explores the role and potential of rapid prototyping as a tool in the product developmentprocess. Through a combination of literature review, interviews, and a case study conducted incollaboration with Saab Aeronautics, the thesis addresses three main research questions: (1) In what wayis rapid prototyping utilized during the product development process? (2) How can rapid prototyping beimplemented when performing a product development project? (3) How can rapid prototyping beintegrated into Saab’s currently used product development methodology? The theoretical study examines traditional product development models together with the usage of rapidprototyping methodologies. It discusses the benefits and drawbacks of rapid prototyping, such asincreased iteration speed, reduced development time, enhanced design flexibility, and limitations relatedto mechanical performance and material constraints. A practical case study was conducted to evaluate the implementation of rapid prototyping in a real-worldscenario. The case study involved the development of a deployment mechanism for releasing a firstperson view drone from an unmanned aerial vehicle. Multiple design iterations were carried out using 3Dprinting and laser cutting to rapidly develop, test, and refine prototypes. The process emphasized earlystage concept evaluation, mechanical testing, and system integration. The results demonstrated thatrapid prototyping contributed to speed and efficiency of design iterations while enabling evaluation ofconcepts at an early stage in development. Based on insights gained from the case study and empirical interviews with Saab personnel, the thesisproposes an approach of integrating rapid prototyping into Saab’s product development process. Thisapproach emphasizes the strategic use of rapid prototyping in early design phases to validate criticalfunctions and interfaces, enabling Saab to meet increasing demands for faster and more agiledevelopment cycles. The study concludes that while rapid prototyping is not a replacement for traditionalmethods, it is a valuable complement that can enhance design quality and responsiveness when appliedsystematically within a structured development process.