Intro.

To Aerospace
Eng. Design

• Design process
outline

• Summary
• A design process flow chart
• How to design
• Formal methods of design
• Gathering information
• Analyzing information
• Obtaining feedback

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What is the process of design

• Design can be viewed as process whereby a problem is solved

with increasing levels of refinement and specificity.
• We may begin with a list of the client’s desires (and user
needs).
• We progress towards a clearly defined plan for fabrication and
implementation.
• This is largely done by asking questions, and knowing how (or
where) to find the answers.

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Summary

1. Clarify and establish the client’s objectives.

2. Identify the constraints that govern the designs.
3. Establish the functions that a design must perform.
4. Determine the means by which these functions can be
performed.
5. Establish the formal requirements of the design.
6. Develop design alternatives

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Summary (Cont.)

7. Model and analyze the design to test and evaluate the design
against the objectives and constraints.
8. Refine and optimize the design to produce the “best”
solution.
9. Document and communicate the design for fabrication.

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A design process flow chart

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Case study

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Problem definition

The steps required to complete the problem definition process

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Conceptual design

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Preliminary design

The steps required to complete the preliminary design process resulting

in the assignment of primary design attributes

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Detailed design

The steps required to complete the detailed design process

where the remaining attributes are defined.

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Design communication

The final step is to communicate the design to he client in an appropriate format

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Iterative process with feedback

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Strategy of least commitment

• During the conceptual design phase, it is important to generate

as many candidate as possible before reducing the choices to
one chosen design.
• It is a good practice to defer the selection of a chosen design
until al design choices have been evaluated.
• In effect, you should be equally uncommitted to all deign
option until you are able to fully compare all your options.

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Divide and conquer

• When dealing with a large and complicated design problem, it

is often effective to break it down into smaller sub-problems.
• It is likely easier to solve a sequence of smaller problems and
recombine your solution in the end.

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Objective trees

• To better understand the client’s problem, we will devise a

hierarchical list or graph of the client’s objectives or goals.
• Similar to our breakdown of tasks in a WBS, we will present
the objectives either as a tree or outline, with higher
abstraction at the top-most level.

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Objective tree (Ladder)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,

Clive L. Dym et al, John Wiley & Sons Inc., 2014
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Objective tree (Juice container)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,

Clive L. Dym et al, John Wiley & Sons Inc., 2014
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Pairwise comparison charts

• To rank the relative importance of our design objectives, we

will use tools such as Pairwise Comparison Charts (PCC) to
objectively compare our objectives.
• This is done by forming a matrix of all the design objectives
and comparing them against one another in pairs.
• By assigning an order of importance for each pair, we can
form a score that indicates a more objective ranking.

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PCC (ladder design)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,

Clive L. Dym et al, John Wiley & Sons Inc., 2014

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PCC (juice container)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,

Clive L. Dym et al, John Wiley & Sons Inc., 2014

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Establishing metrics

• Prior to generating any design ideas, we will need to establish

a fair and objective method for establishing the satisfaction of
a design objective.
• For many objectives, this metric will depend upon a score
using a scale.
• The score
• may be derived from values that we can calculate directly
• Be based upon a rubric applied in an objective manner
• An important characteristic of any metric is that it is
repeatable and unambiguous.

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Scales for awarding points

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,

Clive L. Dym et al, John Wiley & Sons Inc., 2014
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Objective tree and constraints

A combined objectives (rectangles) and constraints (Ovals)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,
Clive L. Dym et al, John Wiley & Sons Inc., 2014
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Functional analysis

• A functional analysis is used to identify what it is that a design

must do.
• One method for doing this is the so-called “black box”
approach, in which the inputs and outputs that cross the
boundaries of the device are considered.
• By assessing the flow of energy, information, or material from
input to output, we can assign a function to the black box to
make this occur.

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Function analysis (Power drill)

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Performance specification method

• To assist in the development of design requirements, we

develop solution-independent specifications of design
attributes and performance.
• Performance specifications provide values or numbers to
attach to a design requirement.
• Using models, simulation, and testing we will be able to
evaluate a design for satisfaction of the design requirements.

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Morphological chart

• A morphological chart is used to identify ways or means by

which a function could be made to occur.
• Functions are expressed as verb-noun action pairs, while
means are specific ways in energy can be converted, material
moved, or information processed.
• A morph chart is a matrix for visualization and comparing all
possible means to obtain a function.
• Conceptual design ideas can then be constructed by selecting
different combinations of means.
• This allows for a structured exploration of the design space.

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Function-means (lighter)

Functions (rectangles) and Means (trapezoid)

Source: “Engineering Design: A Project-Based Introduction, 4th ed.,
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Clive L. Dym et al, John Wiley & Sons Inc., 2014
Literature review

• A literature review is a classical method for researching what

has been done in the past to solve this or similar problems.
• For example, we can search patents, technical literature, and
vendor publications.
• This may be useful for refining the problem definition or idea
generation.
• During detail design, we may need to research applicable
codes or standards, look up material properties, or use
engineering handbooks.

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Survey and focus groups

• To determine the needs of the user, we may conduct user

surveys or questionnaires as par of our market research.
• Surveys may also be used to gather information from the client
or other stakeholders to better define the problem.
• Market research may also use focus groups to test design
alternatives, or to gather information from users.
• This is more commonly used in the production of commercial
products, and requires significant effort to produce statistically
significant results.

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Interviews

• Informal or structured interviews can be used to gather

information during the problem definition stage.
• A structured interview, using a pre-defined list of questions, is
an efficient use of everyone’s time, especially if the questions
are provided to the interviewee in advance.
• However, an informal interview ay provide an opportunity to
develop ideas that may not have been thought of in advance.

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Brainstorming

• Brainstorming is a useful group activity that can provide

further insight if done correctly.
• As discussed previously, brainstorming involves members of a
group taking turns coming up with ideas without immediate
evaluation.
• Brainstorming may be done during the problem definition
stage to question the attributes of the design problem,
• This may then be used to further guide other information
gathering processes.

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Evaluating designs

• Using experiments we can make measures (e.g. measure the

strength of materials).

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Evaluating designs

• During conceptual design, we can test a proof-of-concept to

check if an idea is likely going to satisfy design requirements
under specific conditions.

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Evaluating designs

• By building and testing a prototype we can test a feature of a

final design to confirm function.

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Evaluating designs

• If building a prototype is cost prohibitive, we can use

simulation to model a device and predict its behavior.
• Simulation may be used to determine design details.
• More often than not, simulation is done using computer simulation.

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Design with feedback

• In industry, the design process typically involves feedback

from the client and user during the design process.
• This is typically done as a formal design review at regular
intervals in meetings with stakeholders.

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Design with feedback

• In industry, the design process typically involves feedback

from the client and users during the design process.
• This is typically done as a formal design review at regular
intervals in meetings with stakeholders.
• A formal design review should present a snapshot of the
current design(s) with sufficient detail that the design can be
explored and discussed.
• Stakeholders are provided an opportunity to provide feedback
and constructive criticism.
• A formal design review is helpful as it can expose oversights,
errors, or mistaken assumptions.

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