Senior Design I Dr. K. Sarkar Dr. Robert A. Freeman UT - Pan American Fall 2014 Note: Senior Design course content was compiled by Dr. Robert A. Freeman over more than a decade. Under his tutelage Dr. Kamal Sarkar started offering the same content about four years back. He reformatted the content from Nine Step Design Modules to Five Phases of Design using his more than two decades of diversified industrial experience.

ABET (Accreditation Board for Engineering and Technology) Definition of Design "Engineering design is the process of devising a system, component, or process to meet desired needs. It is a decision-making process (often iterative), in which the basic sciences, mathematics, and engineering sciences are applied to convert resources optimally to meet a stated objective. Among the fundamental elements of the design process are the establishment of objectives and criteria, synthesis, analysis, construction, testing, and evaluation.

ABET The engineering design component of a curriculum must include at least some of the following features: development of student creativity, use of open-ended problems, development and use of design methodology, formulation of design problem statements and specifications, consideration of alternative solutions, feasibility considerations, and detailed system descriptions. Further, it is essential to include a variety of realistic constraints such as economic factors, safety, reliability, aesthetics, ethics, and social impact."

Five Phases of Design Problem Formulation Concept Development Design Embodiment Design Validation DHF (Design History File)

Sources for Concept Ideas: Techniques to Prime Creativity Patents Reference Books and Trade Journals Experts Brainstorming “6-3-5” Method (Members-Ideas-Minutes) Existing Products

Five Phases of Development Phase Three: Design Embodiment Design Calculations Engineering Calculations Numerical Analyses Experimental methods

Phase Three: Design Embodiment (Continued) Communication Tools Engineering Drawings 3D Renderings Analyses Graphs & Plots Pictures Videos

Phase Three: Design Embodiment (Continued) Design for Manufacturability Tolerances Cost-vs-Accuracy Stack-up of Tolerances Shape Stress Concentration Factor Ease of Manufacturing Manufacturing Processes Assembly Processes Cost Analysis (Proto-vs-Production)

Phase Three: Design Embodiment Continued) Bill of Materials iShop Lead Time Priority Color Coding

Final Report Outline (SDI)

Final Report Outline (SDII)

Questions?