The engineering design process is a series of steps that are used to guide us in problem solving and creating effective solutions. The design process typically includes the following:
Problem definition – Identify the problem that needs to be solved, perform preliminary research, and establish criteria and constraints that the solution must meet.
Feasibility study – Perform a feasibility (pre-design or desktop) study to explore different design solutions to the problem and to determine if the proposed solutions are practical, feasible and achievable within timeline and budget constraints.
Concept development – Develop a range of possible design solutions and evaluate and compare them against the established design criteria and constraints to select the most viable option.
Preliminary design – Perform preliminary design and engineering assessment on the selected option to define its system configuration (including features and functionality), specify its attributes (including geometry, materials and components/equipment), develop schematics/diagrams and initial risk reviews and generate CAD models and general arrangement (GA) drawings.
Detailed engineering – Perform detailed design and engineering assessment to refine, optimise and finalise the design, develop engineering reports/specifications, provide updated risk reviews and generate detail engineering/fabrication drawings for manufacture.
In the traditional design process, engineering simulation is usually performed at the detailed engineering stage for design verification, with any modification or optimisation typically limited to non-compliant areas that don’t meet the design criteria. This approach can produce sub-optimal designs that increase development time, increase manufacturing costs and reduce service life.
Our approach is to include simulation during the concept development and preliminary design stages as a means of virtual prototyping to refine and optimise designs prior to detailed engineering, an approach that produces designs with lower development timeframes, lower manufacturing costs and longer service life.
Engineering Design Process
The engineering design process is a structured, iterative approach that guides engineers in solving problems and creating effective solutions. It’s a cyclical process where steps are often revisited and refined as new information is discovered. Here’s an outline of the 12 typical stages involved:
Define the Problem
- Identify the problem that needs to be solved.
- Ask questions to gain a clear understanding of the need or challenge.
- Consider the context and potential users of the solution.
Brainstorm Possible Solutions
- Encourage creativity and generate a wide range of potential solutions without judgment.
- Techniques like brainwashing, SCAMPER, and lateral thinking can be used to spark ideas.
- Consider existing solutions and how they might be adapted or improved.
Research Ideas/Explore Possibilities for your Engineering Design Project
- Conduct research on existing solutions and technologies relevant to the problem.
- Explore the feasibility of different approaches based on available resources and limitations.
- Learn from past successes and failures in similar projects.
Establish Criteria & Constraints
- Define the desired functions and performance requirements of the solution.
- Specify any limitations or restrictions that the design must adhere to, such as:
- Budgetary constraints
- Material limitations
- Safety regulations
- Size and weight limitations
- Sustainability considerations
- Manufacturing capabilities
- Time constraints
Consider Alternative Solutions
- Evaluate all the brainstormed solutions against the established criteria and constraints.
- Consider factors like:
- Functionality: How well does the solution address the identified need?
- Feasibility: Can the solution be realistically implemented considering budget, time, and resources?
- Safety: Does the solution adhere to safety standards and regulations?
- Sustainability: Does the solution minimise environmental impact throughout its lifecycle?
- Maintainability: How easy is it to maintain and repair the solution?
- Select the most promising solution(s) to move forward with for further development.
Develop a Design Proposal
- Create a detailed proposal outlining the chosen design solution. This proposal should typically include:
- A clear and concise description of the solution
- Schematics, diagrams, or sketches illustrating the design concept
- Bill of materials, listing the components required to build the solution
- Explanation of how the solution meets the established criteria and constraints
- Preliminary analysis of potential risks and mitigation strategies
Make a Model or Prototype
- Construct a physical or digital model (prototype) to represent the chosen design solution. Prototypes are crucial for:
- Visualising the design concept in a tangible form
- Testing and evaluating the design’s functionality and performance
- Identifying any design flaws or areas for improvement before committing to final production
Test & Evaluate
- Conduct rigorous testing on the prototype to assess its performance against the design criteria. Testing methods may involve:
- Functional testing: Verify if the prototype accomplishes its intended purpose.
- Performance testing: Measure the key performance metrics of the design.
- Usability testing: Evaluate how easy and intuitive the design is to use.
- Safety testing: Ensure the design adheres to safety standards.
- Analyse the test results to identify areas where the design can be improved.
Refine the Design
- Based on the evaluation results, refine and iterate on the design to address any shortcomings identified during testing.
- This may involve modifying the design concept, materials selection, or incorporating additional features.
Create the Solution
- Once the design is finalised, create the final product based on the approved design specifications and drawings. This stage may involve:
- Manufacturing the solution in-house or contracting a manufacturer
- Assembling the components
- Implementing any necessary quality control procedures
Communicate Results
- Document the design process, including the challenges encountered and the solutions implemented.
- Share the final product and its functionalities with stakeholders and potential users.
- Consider opportunities to improve the design based on feedback received.
Reflect & Improve
- Evaluate the overall effectiveness of the design process.
- Identify areas for improvement in future projects.
- Continuously learn and adapt your approach to problem-solving.
This 12-step engineering design process provides a framework for engineers to approach challenges systematically and creatively. By following these steps and continuously reflecting on the process, engineers can develop innovative and effective solutions that meet the needs of users and society.
