Design & Engineering

EST 200
Dr. Vishnu Rajan
Purpose of the course
● Introduce the UG students the fundamental principles of design
engineering
● Make them understand the steps involved in the design process &
● Familiarize them with the basic tools used and approaches in design
Course Outcomes

CO1 Explain the different concepts and principles involved in design engineering

CO2 Apply design thinking while learning and practicing engineering

CO3 Develop innovative, reliable, sustainable and economically viable designs

incorporating knowledge in engineering
Assessment Pattern
Continuous Internal Evaluation (CIE) Pattern:

Attendance (10), CAT (25), Assignment/Quiz/Course project(15)

End Semester Examination (ESE) Pattern:

Part A : 30 marks
part B : 70 marks

Part A contains 10 questions with 2 questions from each module, having 3 marks for each question. Students should answer all questions.

Part B contains 2 case study questions from each module of which student should answer any one. Each question carry 14 marks and can have
maximum 2 sub questions.
Syllabus - Module 1
Design Process
● Introduction to Design and Engineering Design
● Defining a Design Process
○ Detailing Customer Requirements
○ Setting Design Objectives
○ Identifying Constraints
○ Establishing Functions
○ Generating Design Alternatives
○ Choosing a Design
Introduction to Design and Engineering Design
● Engineering design is the process of devising a system, component,
or process to meet desired needs.
● It is a decision-making process in which the basic sciences,
mathematics, and engineering sciences are applied to optimally
convert resources to meet a stated objective.
● Among the fundamental elements of the design process is the
establishment of objectives and criteria, synthesis, analysis,
construction, testing, and evaluation.
Design Levels
Adaptive design: In the great majority of instances, the designer’s
work will be concerned with the adaptation of existing designs.
Development design: Considerably more scientific training and
design ability are
needed. The designer starts from an existing design, but the final
outcome may differ markedly from the initial product. Example: manual
gearbox in a car to an automatic one
New design: Only a small number of designs are new designs.
Examples: first automobile, airplane, or even the wheel
Important aspects that buyers check
● How it looks?
● Is it reliable?
● What is the cost?

Most of them won't see specs

They won't be having a clue on the manufacturing process

Some may even buy products that are more expensive thinking that the
increase in price will give good quality
Few disasters due to bad engineering design
The Challenger space
shuttle exploded in 1986
after an O-ring seal failed

The design layout of the

fuel tanks was the cause
of the Concorde crash in
2000
Design Requirements
Needs of the customer
Customers are not just end users

Customer deals with the product at some stage of its lifetime

Example: Aeroplane

Additional Examples: Smartphones, College

Design Process
The design process is a sequence of events and guidelines that take a
designer from visualizing a product to realizing it, systematically,
without hindering creativity.

○ Detailing Customer Requirements

○ Setting Design Objectives
○ Identifying Constraints
○ Establishing Functions
○ Generating Design Alternatives
○ Choosing a Design
Identifying customer needs (Requirements)
Abstract Client request: It is often unlikely that the need will
be expressed clearly. The client may know only the type of
product that he or she wants; for example, “I need a safe
ladder.”
Modification of an existing design: Often a client asks for a
modification of an existing artifact to make it simpler and easy
to use.
Generation of a new product: In all profit-oriented industries,
the attention, talent, and abilities of management, engineering,
production, inspection, advertising, marketing, sales, and
servicing are focused on causing the product to return profit for
the company and in turn for company stockholders.
Detailing Customer Requirements
This step involves thoroughly understanding and documenting what the
customer needs and expects from the product. It includes gathering
detailed information about customer preferences, problems they face
with current solutions, and specific features they desire in the new
product.

Importance: Accurately capturing customer requirements ensures that

the final product meets or exceeds customer expectations, leading to
higher satisfaction and successful product adoption.

Example: For designing a new smartphone: - SmartBoard -

● Conduct surveys and focus groups to understand customer preferences for camera quality,
battery life, and design aesthetics.
Setting Design Objectives
Definition: Setting design objectives involves defining clear, measurable goals and
outcomes that the design must achieve. These objectives should align with the
customer requirements and provide a roadmap for the design process.

Importance: Clear design objectives guide the development process, ensuring that
the design stays focused on achieving specific, measurable goals that satisfy
customer needs.

Example: For the smartphone:

● Objectives could include achieving a battery life of 24 hours with normal
usage, ensuring the device weighs less than 150 grams, and supporting the
latest 5G technology.
Identifying Constraints
Definition: This step involves recognizing the limitations and
restrictions within which the design must be developed. Constraints can
include budget limits, material availability, regulatory standards, and
technical limitations.

Importance: Identifying constraints early in the process helps avoid

unrealistic designs and ensures that the final product can be feasibly
developed within the given limitations.

Example: For the smartphone:

● Constraints might include a maximum budget of $300 per unit,
compliance with international safety standards, and a maximum
thickness of 8 mm.
Establishing Functions
Definition: Establishing functions involves determining the specific
features and functionalities that the product must perform to meet
customer needs and design objectives.

Importance: Clearly defined functions ensure that the product will

perform as intended and meet user expectations, providing a clear
basis for design decisions.

Example: For the smartphone:

● Key functions could include a high-resolution camera for quality
photography, a fast processor for smooth multitasking, and robust
security features like fingerprint recognition.
Generating Design Alternatives
Definition: This step involves brainstorming and creating multiple design
options or solutions that could potentially meet the objectives and
functions within the identified constraints. It encourages creativity and
innovation in finding the best possible solution.

Importance: Generating multiple design alternatives allows for

exploration of different approaches and ensures that the best possible
design is selected after thorough evaluation.

Example: For the smartphone:

● Propose different designs with varying screen sizes (5.5 inches vs. 6.5
inches), battery capacities (3000mAh vs. 4000mAh), and materials
(plastic vs. aluminum).
Choosing a Design
Definition: Choosing a design involves evaluating the generated
alternatives based on criteria such as feasibility, cost, performance, and
user feedback, and selecting the best option that balances the
objectives, functions, and constraints.

Importance: This step ensures that the final design is the most
effective and efficient solution, ready to proceed to the prototyping and
testing phases.

Example: For the smartphone:

● Evaluate the proposed designs based on user feedback from focus
groups, cost analysis, and technical feasibility studies. Choose the
design that offers the best balance of features, cost, and user
Designing a New Laptop
Detailing Customer Requirements:

● Conduct market research and customer interviews to understand the need for a lightweight, high-performance laptop with a
long battery life and excellent display quality. Document specific requirements like a weight under 1.5 kg, a battery life of at
least 12 hours, and a 4K display.

Setting Design Objectives:

● Define clear objectives such as achieving the specified weight and battery life, supporting high-resolution displays, and
maintaining a competitive price point.

Identifying Constraints:

● Identify limitations such as a maximum budget for components, compliance with international electronic safety standards, and
a maximum thickness of 1.5 cm.
Designing a New Laptop
Establishing Functions:

● Determine essential functions like fast processing for multitasking, a high-quality keyboard for comfortable typing, and robust
connectivity options like USB-C and Wi-Fi 6.

Generating Design Alternatives:

● Develop several laptop designs with different materials (aluminum vs. plastic), varying battery sizes, and screen technologies
(LCD vs. OLED).

Choosing a Design:

● Evaluate each design based on performance tests, cost analysis, and user feedback. Choose the design that offers the best
balance of performance, aesthetics, and cost-efficiency.
 Designing a self sustaining underwater habitat to stay during
flood/landslides

● Detailing Customer Requirements

● Setting Design Objectives
● Identifying Constraints
● Establishing Functions
● Generating Design Alternatives.
● Choosing a Design
Designing a Self-Sustaining Underwater Habitat to stay during
flood/landslides
Detailing Customer Requirements: Conduct research to understand the need for an underwater habitat
for scientists and explorers. Document requirements like sustainable energy, water purification systems,
carbon dioxide to oxygen conversion, and a comfortable living environment.
Setting Design Objectives: Define objectives such as achieving energy independence, maintaining a
stable internal environment, and ensuring safety.
Identifying Constraints: Identify limitations such as budget, communication, energy levels, space etc
Establishing Functions: Determine essential functions like oxygen generation, waste management, and
communication systems (ELF, GPR, Seismic).
Generating Design Alternatives: Develop several designs with different energy sources (temperature
variations to energy, CO2 to energy etc), structural materials, and water purification methods.
Choosing a Design: Evaluate each design based on sustainability, cost, and safety tests. Choose the
design with the best balance of functionality and sustainability.
Designing a flying vehicle for transporting students

● Detailing Customer Requirements

● Setting Design Objectives
● Identifying Constraints
● Establishing Functions
● Generating Design Alternatives.
● Choosing a Design
Module II
Iterative Design Thinking Process Stages
Understand the users and Generate a wide range of Evaluate prototypes and
their needs. ideas and solutions. gather feedback from users.
Interviews, observations, use Brainstorming, sketching, Observe how users interact,
empathy encourage wild ideas. Gather data on usability

Empathiz Ideate Test

e

Define Prototyp
e

Clearly articulate the Create tangible

problem to be solved. representations of ideas to
Synthesize findings, frame a explore potential solutions.
problem statement Low fidelity, High fidelity
Design Thinking Week 3
Name of the algorithm of Problem solving? - ARIZ

Innovation algorithm - TRIZ

Flip classroom - Role reversal

Tyre wear - Aircraft

 1. Empathize
Objective: To deeply understand the needs, experiences, and emotions of the users for whom
you are designing.

Activities:

● Engage with users through interviews, observations, and interactions.

● Immerse yourself in their environment to gain insights into their challenges and
behaviors.
● Collect qualitative data that reveals users' needs, desires, and pain points.

Outcome: A comprehensive understanding of the user's perspective, allowing you to develop a

user-centered design. This stage helps in uncovering insights that may not be immediately
obvious but are crucial for effective problem-solving.

Example: Insights like "Elderly users need larger, more visible icons and simplified
navigation," or "Business professionals require longer battery life and seamless
multitasking capabilities."
2. Define
Objective: To clearly articulate the problem you are trying to solve based on the insights gathered during the Empathize stage.

Activities:

● Synthesize the information gathered to identify patterns and themes.

● Develop problem statements that define the challenge from the user's perspective.
● Focus on defining a meaningful problem that is specific and actionable.

Outcome: A well-defined problem statement that guides the design process, ensuring that the solutions developed are relevant and
targeted to the users' needs.

Example:
● Synthesize the data collected and identify key problems, such as "Elderly users struggle with complex interfaces" or
"Battery life is a critical issue for users on the go."
● Formulate a problem statement: "Design a mobile phone that is easy for elderly users to navigate and that also has an
extended battery life for professionals."
3. Ideate
Objective: To generate a wide range of creative ideas that address the problem defined in the previous stage.

Activities:

● Brainstorming sessions where quantity is encouraged over quality to explore all possible solutions.
● Use techniques like mind mapping, sketching, and storyboarding to visualize ideas.
● Encourage a collaborative environment where all ideas are welcome, and there are no bad ideas.

Outcome: A diverse collection of potential solutions, which will later be narrowed down and refined based on feasibility and relevance to
the user needs.

Example:
● Brainstorm ideas such as creating a simplified user interface with larger icons and fonts, incorporating a high-capacity
battery, and adding customizable shortcuts for frequently used apps.
● Consider innovative features like a voice assistant tailored for elderly users or a modular battery pack that can be swapped
out on the go.
● Encourage diverse thinking, such as exploring different form factors like foldable phones that might better cater to various
user needs.
4. Prototype
Objective: To create tangible representations of your ideas so they can be tested and refined.

Activities:

● Develop low-fidelity prototypes, such as sketches, models, or digital mockups, that allow for quick iteration.
● Focus on key features and functions rather than a polished final product.
● Use the prototypes to explore different solutions and get feedback from users and stakeholders.

Outcome: A physical or digital prototype that can be tested with users, allowing you to gather feedback and make
improvements before moving on to the final design.

Example:

● Create a low-fidelity prototype of the phone’s interface, such as a clickable wireframe that simulates
the simplified navigation.
● Build a physical model of the phone with a removable battery pack or a prototype that mimics the feel and
usability of a foldable screen.
● Focus on key features, like testing the accessibility of the interface with larger fonts or the user experience
of the modular battery.
5. Test
Objective: To evaluate the effectiveness of the prototypes by testing them with users.

Activities:

● Conduct user testing sessions where the prototypes are interacted with by real users.
● Observe how users interact with the prototype, noting any difficulties or areas for improvement.
● Gather feedback through surveys, interviews, or direct observation to understand how well the solution
meets the users' needs.

Outcome: Insights into how the prototype performs in a real-world scenario, leading to further refinement or
iteration of the design. Testing helps in validating the design and ensuring that the final product is both functional
and user-friendly.

Example:

● Conduct user testing sessions where elderly users interact with the simplified UI prototype, observing if
they find it easier to use and navigate.
● Test the battery life with business professionals during a typical workday, gathering feedback on
whether the battery meets their needs.
Design Thinking as Divergent-Convergent Questioning

Design Thinking as Divergent-Convergent Questioning is a framework

that emphasizes the balance between generating a wide range of ideas
(divergent thinking) and then narrowing down those ideas to select the
most effective solutions (convergent thinking). So 2 steps are there:
● Divergent Thinking
● Convergent Thinking
Divergent Thinking
Purpose: This stage is about exploring a variety of possibilities, encouraging creativity, and
thinking broadly without constraints. The goal is to generate as many ideas or solutions as
possible, even if they seem unconventional or impractical.

Process:

Brainstorming: Encouraging free-flowing ideas.

Mind Mapping: Visually organizing information to show relationships between different

concepts.

Research and Exploration: Gathering insights from diverse sources to inspire new
thinking.

Mindset: Open, inclusive, and non-judgmental, with a focus on quantity over quality of ideas.
Convergent Thinking
Purpose: After the divergent phase, the focus shifts to narrowing down the
ideas. This involves critically evaluating the options, selecting the most feasible
ones, and refining them into a coherent solution.
Process:

● Analysis and Synthesis: Reviewing and combining ideas to find

connections and potential solutions.
● Prioritization: Ranking ideas based on criteria like feasibility, impact, and
alignment with goals.
● Decision-Making: Choosing the best solution(s) to move forward with.

Mindset: Critical, analytical, and focused, with an emphasis on practicality and

effectiveness.
Application in Design Thinking
Design Thinking integrates these two approaches throughout its iterative stages:

1. Empathize: Divergent thinking to understand user needs broadly.

2. Define: Convergent thinking to focus on a specific problem.
3. Ideate: Divergent thinking to generate a wide range of ideas.
4. Prototype: Convergent thinking to select and build the most promising
ideas.
5. Test: Both divergent (exploring new insights) and convergent (refining
solutions) thinking to improve the design.

By alternating between divergent and convergent thinking, designers can explore

innovative solutions while ensuring they meet user needs and constraints
effectively. This balance is crucial for solving complex problems in creative yet
practical ways.
Module 3
Design Communication (Languages of Engineering Design):-
● Communicating Designs Graphically
● Communicating Designs Orally and in Writing
● Mathematical Modeling In Design
● Prototyping and Proofing the Design
Design communication
Process by which engineers, designers, and stakeholders share and
exchange ideas, concepts, and technical details related to a design
project.

Integral part of the engineering design process

It ensures that all parties involved have a clear understanding of the

design intentions, requirements, and outcomes.

Effective design communication is essential for the success of any

project
Design communication
It facilitates collaboration, reduces misunderstandings, and helps in
achieving the desired results.

It bridges the gap between abstract ideas and practical implementation.

It allows designers to convey their vision in a manner that can be

understood by different audiences, including clients, team members,
manufacturers, and end-users.

The process of design communication involves multiple forms of

expression, such as visual, verbal, and written, each serving a specific
purpose in the overall design workflow.
Key Objectives of Design Communication
1. Clarity: One of the primary objectives of design communication is to ensure
that the design intent is conveyed clearly and unambiguously. This helps in
aligning the understanding of all stakeholders, minimizing the risk of errors or
misinterpretations.
2. Collaboration: Design projects often involve multidisciplinary teams working
together. Effective communication fosters collaboration among team
members, enabling them to share ideas, provide feedback, and contribute to
the development of the design.
Key Objectives of Design Communication
1. Documentation: Thorough communication ensures that the design process
is well-documented, creating a reference that can be used throughout the
project's lifecycle. This documentation is crucial for future modifications,
manufacturing, and maintenance.
2. Feedback and Iteration: Design communication is a two-way process that
not only involves presenting ideas but also receiving feedback. This feedback
is essential for iterative development, where designs are refined and
improved based on input from stakeholders.
3. Persuasion: In many cases, designers need to persuade clients or decision-
makers of the viability and value of a design. Effective communication is key
to presenting compelling arguments and justifications for design choices.
4. Compliance and Standards: Engineering designs must often adhere to
industry standards, regulations, and client specifications. Clear
communication ensures that these requirements are understood and met
Challenges in Design Communication
● Complexity: Engineering designs can be complex, involving numerous technical
details. Simplifying these details without losing essential information can be
challenging.
● Audience Diversity: Different stakeholders may have varying levels of technical
knowledge. Communicating designs in a way that is accessible to all, from technical
experts to non-technical clients, requires skill and adaptability.
● Iteration and Updates: Design is an iterative process, with frequent updates and
changes. Keeping all stakeholders informed and ensuring that communication is
consistent throughout the process is critical.
Importance of Design Communication in Engineering

● In engineering, the success of a project is often determined not just

by the quality of the design itself, but by how well that design is
communicated to those responsible for bringing it to life.
● Whether it’s through visual representations, technical
documentation, or verbal presentations, the ability to communicate
a design effectively ensures that the final product aligns with the
original vision and meets the intended purpose.
● Without clear communication, even the most innovative designs can
fail during implementation due to misinterpretation or lack of
understanding.
Communicating Designs Graphically
● Engineering Drawings: Use standardized symbols, notations, and
views (e.g., orthographic, isometric) to visually represent components
and assemblies.
● CAD Models: Digital representations using software tools like AutoCAD,
SolidWorks, or CATIA that provide precise, scalable images for 3D
visualization.
● Diagrams and Flowcharts: Useful for depicting system processes,
workflows, and relationships between components in a simplified
manner.
● Sketches: Quick, freehand drawings that convey initial ideas and
concepts during the early stages of design.
Communicating Designs Orally and in Writing
Oral Presentations:

● Objective: Clearly explain design concepts, justifications, and outcomes to

stakeholders.
● Tools: PowerPoint slides, visual aids, and models to support the narrative.
● Key Aspects: Clarity, structure, engagement with the audience, and addressing
potential questions.

Written Reports:

● Content: Design objectives, methodologies, analysis, results, and conclusions.

● Formats: Design briefs, technical reports, research papers, and user manuals.
● Technical Documentation: Detailed, clear, and precise documentation to
ensure the design can be replicated, reviewed, and implemented.

Emails and Memos: Communicate specific aspects of the design process, updates,
Mathematical Modeling in Design
Purpose: Provides a mathematical representation of the physical systems
to predict behavior, optimize designs, and validate concepts.
Types of Models:

● Analytical Models: Use equations derived from physics and

mathematics to represent system behavior.
● Numerical Models: Employ computational methods (e.g., Finite
Element Analysis, Computational Fluid Dynamics) to simulate complex
systems.

Applications: Used for stress analysis, thermal analysis, fluid dynamics,

and other performance evaluations.