This paper is a case study conducted to present an approach to the process of designing

new products using virtual prototyping. During the first stage of research a digital geometric

model of the vehicle was created. Secondly it underwent a series of tests utilising the

multibody system method in order to determine the forces and displacements in selected

construction nodes of the vehicle during its movement on an uneven surface. In consequence

the most dangerous case of loads was identified. The obtained results were used to conduct

detailed strength testing of the bicycle frame and changes its geometry. For the purposes

of this case study two FEA software environments (Inventor and SolidWorks) were used. It

has been confirmed that using method allows to implement the process of creating a new

product more effectively as well as to assess the influence of the conditions of its usage more

efficiently. It was stated that using of different software environments increases the complexity

of the technical process of production preparation but at the same time increases the

certainty of prototype testing. The presented example of simulation calculations made for

the bicycle can be considered as a useful method for calculating other prototypes with high

complexity of construction due to its systematized character of chosen conditions and testing

procedure. It allows to verify the correctness of construction, functionality and perform

many analyses, which can contribute to the elimination of possible errors as early as at the

construction stage.

The study is devoted to the co-design concept which is not widely studied in the manufacturing industry area. The concept is just practiced but not theorized and not investigated enough, although it greatly deserves it because of its perspectives and advantages potential in the technology changes era. This study aims to present an investigation of literature views on co-design in manufacturing operations, with the comparison to service literature where it is widely discussed; the study also aims at in-depth investigations of co-design occurrences in two industrial cases of product development to understand their nature and circumstances. In addition, the influence of Industry 4.0 technologies and their coexistence with the concept of sustainability will also be strongly taken into consideration in the empirical part of this study. The process of the individualized production of the industrial line for animal food packing and cardboard packaging production has been studied according to case study methodology. The study demonstrates that co-design could contribute to bettering the process of new product development and achieving products more accurate for the final users’ requirements. It goes hand in hand with one of the core ideas of sustainability, which is to have long-lasting products, exploited by the customer with a high level of satisfaction for a longer time. The study implies that the technologies of Industry 4.0 could support wider and more effective co-design exploitation by manufacturing entities.

Production is becoming more customer-focused as it departs from delivering standardized mass products to market segments, and the emerging Industry 4.0 technologies render this much easier than before. These technologies enable two-way information exchange with customers throughout all the steps of product development, particularly in terms of tailor-made products. This study aims at presenting proposals of implementing Industry 4.0 technologies into the process of tailored products, where the product is customized for the customer from the start and where adjustments are also made at the manufacturing stage. The study also aims to build a concept of intensification of customer contact and to improve the process flow by applying Industry 4.0 technologies. The study’s subject is tailor-made furniture production, with individually designed products that are manufactured and installed at a customer’s facilities. The company in the study operates on a small scale. The study employs a case study methodology that shows how the process can be improved in terms of real-time effective customer contact and process flow. The huge potential of 3D visualization as well as augmented and virtual reality technologies are also demonstrated. The study concludes with several directions for further development of existing technology solutions.