1. 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.

2. 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.

3. 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."

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

5. 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

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

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

8. 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)

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

10. Final Report Outline (SDI)

11. Final Report Outline (SDII)

12. Questions?