Transforming Design Reviews with Immersive Visualisation and Ergonomic Analysis
Design reviews are a critical part of the product development lifecycle. During this phase, teams meet regularly to review 3D models, make design changes, and identify any issues before moving on to the next stage. Traditionally, this involves reviewing 3D data on a 2D screen, which can lead to challenges when trying to apply physical context and scale to the model. This often results in oversights and misunderstandings of critical design details.
Once the design review is complete, 3D prototypes are usually produced, and the review process starts again. As an iterative process, this can become time-consuming and costly, especially when late-stage changes are required. However, after the final design iteration is approved, the focus shifts to production.
While many modern manufacturing processes are automated, most still rely on human input to ensure operations run smoothly. Therefore, organisations need to ensure that both designs and factory layouts are optimised for human interaction, allowing employees to work safely and comfortably without compromising on efficiency.
Prioritising human factors and ergonomics in design reviews
Human factors and ergonomics are now integral to the design review process and should be considered early on. These disciplines focus on the relationship between the user, equipment, and environment, aiming to reduce the likelihood of human error, lower overall lifecycle costs, improve safety, and enhance system performance.
By conducting a thorough ergonomic analysis, teams can critically evaluate three key areas:
- Human factors: assessing seat sizes, reach distances to controls, access panels, buttons, and interfaces.
- Task design: focusing on the order of tasks, ease of use, and avoiding information overload.
- Machine design: reviewing mechanical arrangements for access, serviceability, and maintenance.
However, these considerations are often introduced too late in the design process, once production is already underway. Failing to include a detailed human factor analysis can lead to increased risk of injury and create unsafe working environments. Furthermore, addressing ergonomic issues as an afterthought can result in costly and time-consuming changes, which can cascade through the product lifecycle and cause significant delays.
The risks associated with poor human factors can be mitigated by identifying potential issues as early as possible in the design review process and continuing to update them throughout. But how can these critical elements be evaluated effectively when design reviews are carried out on a 2D screen?
Immersive technology revolutionises design reviews by combining real people with virtual designs
Immersive visualisation technology is transforming the way engineering data is accessed and reviewed. Design reviews are one of the best ways to leverage the benefits of these innovative tools. By using head-mounted displays (HMDs), Powerwalls, or CAVE systems, teams can visualise and interact with their 3D models in context and at scale. This gives the model the spatial context necessary to highlight new ideas and address problems that would be difficult to explain out of context.
It’s at this early point that incorporating the human factor becomes critical. Immersive visualisation technology lends itself perfectly to ergonomic analysis by allowing the inclusion of 1:1 scale virtual manikins that represent the real people who will be involved in the process.
How virtual manikins aid ergonomic analysis
Virtual manikins can be manipulated and positioned using Inverse Kinematics (IK) and Forward Kinematics (FK) to represent real human poses and actions within the model. By doing this, designers can answer important questions around reach, fit, and access. These manikins are fully scalable, meaning their height and limb lengths can be adjusted to match the specific person performing the task.
Ergonomic analysis relies on anthropometric data—standard measurements used to assess the fit between people and the environments they interact with. Virtual manikins allow for precise point-to-point measurements across both the model itself and between the manikin and its surrounding environment. Engineers and Human Factors specialists can easily measure these virtual figures and cross-reference them with anthropometric data to ensure that design specifications meet real-world needs.
Using this innovative combination of immersive technology and robust processes enables teams to achieve high productivity, quality results, and ensure health and safety in both the design and production phases.
Incorporating manikins into your design review process
Virtalis’ latest release of Visionary Render software includes the addition of 1:1 scale manikins, making it easier than ever to conduct ergonomic analysis during design reviews. Visionary Render is an enterprise-ready software solution that allows users to import engineering data assets, build bespoke virtual scenes, and interact with their models in a fully immersive environment.
In these virtual scenes, teams can collaborate either locally or remotely on tasks such as:
- Design reviews
- Factory layout planning
- Training
- Operations and maintenance
By engaging teams at every step of the product lifecycle, organisations can reduce costs, mitigate risks, and deliver more ambitious projects with greater confidence. The inclusion of virtual manikins in Visionary Render adds a powerful new dimension to design reviews, ensuring that human factors are accounted for from the very beginning.
Discover the benefits of immersive design reviews with Virtalis
Are you ready to revolutionise your design review process and improve human factor analysis? Virtalis is here to help. Our latest innovations in immersive visualisation technology are designed to enhance your workflow, ensuring that your products are optimised for both human interaction and manufacturing efficiency.
Get in touch to arrange a demo and experience the benefits of Visionary Render and its manikin feature for yourself. Visit Virtalis to schedule your demo today!