1. Prototyping: “The Design Process”

2. The Problem The design process begins when a solution to a problem is needed. At other times the engineer may change an existing design. (If the handle of a pot becomes too hot to touch, it must be redesigned.) Engineers also improve existing products. They make the product work even better.

3. Investigation of the Problem When designing a product you must consider the following: FUNCTION: A functional object must solve the problem described in the design brief. The basic question to ask is : "What, exactly, is the use of the article?" APPEARANCE: How will the object look? The shape, color, and texture should make the object attractive. MATERIALS: What materials are available to you? You should think about the cost of these materials. Are they affordable? Do they have the right physical properties, such as strength, rigidity, color, and durability? CONSTRUCTION: Will it be hard to make? Consider what methods you will need to cut, shape, form, join, and finish the material. SAFETY: The object you design must be safe to use. It should not cause accidents.

4. Developing Alternative Solutions When using the design process, you should produce a number of solutions. It is very important that you write or draw every idea on paper as it occurs to you. This will help you remember and describe them more clearly. It is also easier to discuss them with other people if you have a drawing. These first sketches do not have to be very detailed or accurate. They should be made quickly. The important thing is to record all your ideas. Do not be critical. Try to think of lots of ideas, even some wild ones. The more ideas you have, the more likely you are to end up with a good solution.

5. Choosing a Solution You must also consider: Your own skills. The materials available. Time needed to build each solution. Cost of each solution. Deciding among the several possible solutions is not always easy. It helps to summarize the design requirements and multiple solutions. Which would you choose? In many cases, let it be the one you like best.

6. Models and Prototypes A model: is a full-size or small-scale simulation of an object. Architects, engineers, and most designers use models. Models are one more step in communicating an idea. It is far easier to understand an idea when seen in three-dimensional form. A scale model is used when designing objects that are very large. A prototype: is the first working version of the engineeers solution. It is generally full-size and often handmade. For a simple object, the engineer probably would not make a model. He or she may go directly to a prototype.

7. Testing and Evaluation Testing and evaluating answers three basic questions: Does it work? Does it meet the design brief? Will modifications improve the solution? The question "does it work?" is basic to good design. It has to be answered. This same question would be asked by an engineer designing a bridge, by the designer of a subway car, or by an architect planning a new building. If you were to make a mistake in the final design of the pencil holder what would happen? The result might simply be unattractive. At worst, the holder would not work well. Not so if a designer makes mistakes in a car's seat belt design. Someone's life may be in danger!

8. Detailed Drawings In the next step, make a detailed drawing of the chosen solution. This drawing must include all of the information needed to make your product. It should include the following: The overall dimensions Detailed dimensions The material to be used How it will be made What finish will be required Now you can choose what to do next. You can make a model and later a prototype.

9. Reverse Engineering What is reverse engineering? Reverse engineering is the process of discovering the technological principles of a device, object or system through analysis of its structure, function and operation.process discovering deviceobjectsystemanalysis structurefunctionoperation It often involves taking something (e.g., a mechanical device, electronic component, or software program) apart and analyzing its workings in detail. mechanical deviceelectronic component software Or, to try to make a new device or program that does the same thing without copying anything from the original.

10. The Design Brief Introduction The purpose of this design brief is to introduce the student to the process of prototyping an item. Challenge Using a standard soda can, the student will design, and build a small box. Objective Using the design process reviewed in class the student will complete: 1.Model #1, constructed from paper, 2.Prototype #1, constructed from lightweight sheet metal, provided by the soda can, 3.A Complete step by step assembly plan. Resources Internet, Library, Completed student drawings.

11. The Design Brief Procedures The student will follow the design process as described in class, The student will provide hand drawn isometric sketches of the completed box, complete with measurements, Completed sketches will be drawn on 8.5” x 11” paper, #2 pencil will be used, Sketches must be neat, and easy to read, The completed box must use material from one standard soda can, The box must be constructed of 1 piece of metal, The completed box must be a square, triangle, or rectangle, The completed design must include a smooth finish, suitable for use by young children. Timeline 3 class periods Evaluation/Assessment 1.Completion of Model #1, 2.Completion of Prototype #2, 3.Creativity, 4.Projected completed within timeline, 5.Overall project appearance