Week 6: Lecture Notes

Detailed Design and Testing

Process ends with a device / product / structure / algorithm that is verified to meet
those needs.
Final stage takes System Design to prototype of fully functioning system.

Detailed Design

Detailed Design determines what is the mechanical, electrical, structural and other
types of physical variations there may be and detail is specification around that
component, the part that we buy or the part that we put in.
Example; Requirement for passenger vehicle, physical allocation certain amount
of seats in front and certain amount in the back. Component engineering portion
there would be a choice around the propulsion e.g. internal combustion engine or
electrical drive train.
The components come in the detailed design phase.
Morphological Chart Method: - aim of the morphological chart method is to
generate the complete range of alternative design solutions for a product, and
hence to widen the search for potential new solutions. It is a physical design tool,
which allows you to examine different physical implementations of something.
Select amongst those using some criteria.

Systematic Design Model/Systems Engineering

Planning and task clarification, conceptual design, embodiment design, detailed

design. However these EXAMPLES are NOT tested in exam.

Testing

Having done all our design process, now we evaluate if that design process did
what it said it was going to do. We do a design realisation and evaluation process
where we do verification and validation. Difference between verification and
validation is that verification is step by step whilst validation is the over arching
end-to-end, defining these can be in the exam.
Design Verification: o Analysis the use of mathematical modelling and analytical techniques to
predict the compliance of a design to its requirements.
o Inspection the visual examination of the system, component, or
subsystem. It is generally used to verify physical design features.
o Demonstration the use of system, subsystem, or component operation to
show that a requirement can be achieved by the system. Used for a basic
confirmation of performance capability, but lacks detail.
o Test the use of system or component operation to obtain detailed data to
verify performance or to provide information to verify performance
through further analysis. Testing is the detailed quantifying method of
verification and is required to verify the system design.

Verification Testing: - relates back to the approved requirements and can be

performed at different stages during the product life cycle. It is used during the
development of the product.
Validation Testing: - is conducted under realistic conditions on any end product to
determine effectiveness and sustainability of the product.
Each test phase has a corresponding phase on the development side in which the
testing benchmarks were set.

Design Reviews

Keeps team members up-to-date on state of design and enables other stakeholders
input to critical design decisions.
Usually conducted at every important milestones, must be done at these 3 times: o Completion of Requirement Specification
o System Specification
o Detailed design System test
A design review should be held at these key points; prior to order acceptance,
prior to detail design, at suitable points during detail design.

Design for Manufacturing / Industrial Design / 3D Printing for

Component Manufacture

Must always be feasible to be manufactured, consider this in the early stages of

design, integrate product design with process planning and design.

DFMA - Design for Manufacture and Assembly

Exposes cost and quality problems early in the design process, objectively
assesses design simplification opportunities, drives optimisation of product costs.
Design for Assembly (DFA): - DFA minimizes total product cost by targeting;
part count which is the major product cost driver, assembly time, part cost,
assembly process, assembled with single linear motion, part is secured
immediately upon insertion, using fewer standard components, design products to
maximise accessibility during manufacturing and subsequent repairs and
maintenance.
Design for Manufacture (DFM): - DFM is a development practice emphasising
manufacturing issues throughout the product development process; optimise
design for production readiness, aimed at minimising the cost of production while
maintaining an appropriate level of quality, prevents producing expensive designs
that are difficult to manufacture, this is done by having a multidiscipline team
which include personnel from manufacturing, this is an industrial designer.
Design for X (DFX): - It is essentially another constraint on your design e.g.
Design for human interaction, safety, design for logistics, design for environment.

Industrial Design

Five critical goals of industrial design are; utility (products human interface
should be safe, easy to use and intuitive), appearance, ease of maintenance, low

costs, communication (design should communicate the corporate design

philosophy and mission through visual qualities of the product)
Industrial designer comes into play in the concept development phase, starting of
by producing concept sketches then concept models, renderings, control drawings
and models. Also assist seeing this fulfilled in production, as there will be
challenges and variations to the design when building the product, use their
engineering knowledge when doing this.
Industrial design provides a link to the users: - as in the course of product
development, many concerns take precedence: schedule, budget, technical issues,
manufacturing, distribution, and budget.
Industrial designers are communicators: - The various means of visual expression
generated by industrial designers speak much louder than words.
Explore multiple conceptual directions early in the process: - The exploration
process, developing many different solutions to a problem, energizes industrial
designers.
Design refinement is key to a point: - Product refinement is critical to a successful
product, but one cant tinker forever. Resolving details, fine-tuning aspects of the
design for user delight is very important, but so is sticking to a reasonable
schedule.
Industrial designers strive for simple elegance: - Simple, easy-to-use, and
attractive products should be the goal of product development.

10 Principles for Good Design

1. Good design is innovative
2. Good design makes a product useful
3. Good design is aesthetic
4. Good design makes a product understandable
5. Good design is unobtrusive (products fulfilling a purpose are like tools)
6. Good design is honest (doesnt manipulate consumer with fake promises)
7. Good design is long lasting
8. Good design is thorough, down to the last detail
9. Good design is environmentally friendly
10. Good design is as little design as possible

3D Printing for Component Manufacturing

3D printing is a way of rapid prototyping to provide aesthetic visualization, form

fit and function testing and casting models.
3D printing reduces product realisation time allowing shorter entry time to
market, reduced design time results in reduced cost and improved response to
market changes.