SkillDzire

Product Design
 SkillDzire Product Design Schedule

❖ Introduction to Product Development

❖ Understanding Product Life Cycle

❖ Mechanical Design Fundamentals

❖ Advanced Mechanical Design Concepts

❖ Practical Application in Real-Time Projects

❖ Principles of Design for Manufacturability

❖ Advanced DFMA Techniques

❖ Introduction to Casting Processes

❖ Advanced Casting Techniques

❖ Forging Processes and Applications

❖ Further Insights into Forging

❖ Sheet Metal Fabrication

❖ 3D Modeling for Product Design

❖ Advanced 3D Modeling Techniques

❖ Plastic Components Design

Key Highlights:

❖ 4 Short Quizzes

❖ 2 Grand Assessments

❖ 5 Hands on Projects
Week 1: Introduction to Product Development

Topic Covered: Product Development Life Cycle

Description:

Week 1 serves as a foundational exploration into the intricate process of product development,
focusing particularly on the Product Development Life Cycle (PDLC). This week is pivotal as it
provides participants with a comprehensive overview of the stages involved in bringing a product
from conception to market.

Participants delve into understanding the essence of PDLC, which encompasses a series of steps
aimed at systematically designing, developing, and launching a product that meets market needs and
fulfills customer expectations. Through interactive lectures, case studies, and real-world examples,
students gain insights into each stage of the PDLC, understanding its significance and the activities
involved at every step. The week begins by introducing the concept of PDLC, emphasizing its role as
a structured framework that guides product development activities. Participants explore the various
stages typically included in the PDLC, such as ideation, conceptualization, design, prototyping,
testing, manufacturing, and commercialization.

Moreover, students learn about the importance of cross-functional collaboration and interdisciplinary
teamwork throughout the product development journey. They gain an appreciation for the diverse
skill sets and expertise required at different stages of the PDLC, highlighting the collaborative nature
of product development initiatives.

Furthermore, the week provides an opportunity for participants to grasp the significance of market
research, user feedback, and iteration in refining product designs and enhancing market fit. By
understanding customer needs and preferences, participants can effectively tailor their product
development strategies to address specific market demands and capitalize on emerging opportunities.

In essence, Week 1 sets the stage for a holistic understanding of product development, laying the
groundwork for participants to navigate the complexities of the PDLC with clarity, purpose, and
strategic foresight. Through a blend of theoretical knowledge and practical insights, students are
equipped to embark on a transformative journey into the dynamic world of product innovation and
development.
Week 2: Understanding Product Life Cycle

Topic Covered: Product Life Cycle (PLC)

Description:

Week 2 delves into the intricate concept of the Product Life Cycle (PLC), which serves as a
fundamental framework for understanding the evolution of products in the marketplace. Participants
explore the various stages that a product typically progresses through during its lifetime, from
introduction to decline, and gain insights into the strategies applicable at each stage to maximize
profitability and market success.

The week begins with an overview of the Product Life Cycle (PLC), emphasizing its significance as
a dynamic model that traces the trajectory of a product's sales and profitability over time. Participants
learn about the distinct stages of the PLC, including introduction, growth, maturity, and decline, and
examine the characteristics and challenges associated with each phase. Through interactive lectures,
case studies, and real-world examples, participants gain a deeper understanding of the factors
influencing the duration and dynamics of each stage in the PLC. They explore the role of market
demand, competitive forces, technological advancements, and consumer preferences in shaping the
trajectory of a product's life cycle. Moreover, participants analyze the implications of the PLC for
strategic decision-making and marketing planning. They examine the different strategies and tactics
employed by businesses to manage products at various stages of the PLC, such as product
differentiation, pricing adjustments, promotional campaigns, and extension strategies.

Furthermore, participants explore the concept of product portfolio management within the context of
the PLC, considering how organizations strategically allocate resources and prioritize investments
across a portfolio of products with diverse life cycle stages. They discuss the importance of balancing
investments in new product development with efforts to sustain and optimize the performance of
existing products.

In essence, Week 2 equips participants with a nuanced understanding of the Product Life Cycle (PLC)
and its implications for product management and marketing strategy. By comprehending the
dynamics of product evolution and the strategies applicable at each stage of the PLC, participants are
better prepared to navigate the complexities of the marketplace and drive sustained business growth
and innovation.
Week 3: Mechanical Design Fundamentals

Topic Covered: Mechanical Design & Considerations - Part 1.

Description:

Week 3 marks the initiation into the realm of mechanical design, where participants delve into the
fundamental principles and considerations essential for designing robust and efficient mechanical
systems. This session primarily focuses on the foundational aspects of mechanical design, including
material selection, structural integrity, and design principles.

Participants are introduced to the critical role of material selection in mechanical design and its
profound impact on the performance, durability, and cost-effectiveness of engineered products. They
explore various types of engineering materials, such as metals, polymers, ceramics, and composites,
and learn how to evaluate their mechanical properties, including strength, stiffness, toughness, and
corrosion resistance.

Moreover, participants delve into the principles of structural integrity and load analysis,
understanding how mechanical components and systems withstand external forces and stresses. They
learn about key concepts such as stress, strain, deformation, and failure modes, and explore analytical
techniques for assessing the structural integrity of mechanical designs.

Throughout the session, participants engage in hands-on activities, case studies, and design exercises
to apply the principles learned in real-world scenarios. They analyze examples of mechanical
components and systems, identify design flaws and optimization opportunities, and propose solutions
to enhance performance and reliability.

By the end of Week 3, participants develop a solid foundation in mechanical design fundamentals,
equipped with the knowledge and skills necessary to embark on more advanced topics in mechanical
engineering. They gain a deeper appreciation for the intricate interplay between material selection,
structural integrity, and design optimization in the creation of innovative and resilient mechanical
systems.
Week 4: Advanced Mechanical Design Concepts

Topic Covered: Mechanical Design & Considerations - Part 2

Description:

Week 4 elevates participants' understanding of mechanical design as they delve deeper into advanced
concepts and methodologies. Building upon the foundational principles introduced in the previous
week, this session focuses on refining design strategies and exploring sophisticated techniques to
optimize mechanical systems.

Participants begin by exploring tolerance analysis, a critical aspect of mechanical design that involves
assessing the variation in dimensions and tolerances of individual components within an assembly.
They learn how to perform tolerance stack-up analysis to predict the cumulative effects of
dimensional variations on assembly fit, functionality, and manufacturability. Through hands-on
exercises and case studies, participants gain proficiency in identifying tolerance issues, determining
appropriate tolerances, and implementing tolerance optimization strategies to improve product
quality and performance.

Furthermore, participants delve into optimization techniques aimed at enhancing the efficiency,
reliability, and cost-effectiveness of mechanical designs. They explore methods such as parametric
optimization, topology optimization, and finite element analysis (FEA) to systematically improve
design parameters while considering constraints such as weight, material usage, and manufacturing
constraints. Through practical applications and simulations, participants gain insights into the
iterative process of design optimization, where they iteratively refine designs to achieve desired
performance objectives.

By the conclusion of Week 4, participants emerge with a deeper appreciation for the intricacies of
advanced mechanical design concepts and their significance in creating robust and optimized
mechanical systems. They are equipped with practical skills and analytical tools to address complex
design challenges and drive innovation in mechanical engineering.
Week 5: Practical Application in Real-Time Projects

Topic Covered: Real-Time Project.

Description:

Week 5 marks a pivotal transition from theoretical learning to practical application as participants
engage in real-time projects. This immersive experience offers an invaluable opportunity for students
to bridge the gap between classroom instruction and real-world scenarios, fostering the development
of essential skills and competencies in product design and development.

In this week's session, participants embark on hands-on projects that simulate real-world design
challenges encountered in various industries. Guided by experienced mentors or instructors, students
apply the theoretical knowledge acquired in previous weeks to solve practical problems, design
innovative solutions, and navigate the complexities of product development processes.

The real-time projects encompass a diverse range of design tasks, spanning concept ideation,
prototyping, testing, and iteration. Participants collaborate in teams or work independently, depending
on the project scope, to brainstorm ideas, develop conceptual designs, create detailed drawings or
models, and validate their designs through testing and analysis.

Throughout the project duration, participants are encouraged to apply critical thinking, problem-
solving skills, and creativity to overcome obstacles and deliver viable solutions. They learn to
navigate constraints such as budgetary limitations, time constraints, and technical requirements while
striving to meet project objectives and stakeholder expectations.

By actively engaging in real-time projects, participants not only reinforce their understanding of
theoretical concepts but also cultivate essential competencies such as project management, teamwork,
communication, and adaptability. Moreover, the hands-on experience gained during this week
empowers students to transition seamlessly from academic settings to professional environments,
equipped with the practical skills and confidence needed to excel in the field of product design and
development.
Week 6: Principles of Design for Manufacturability

Topic Covered: DFMA - Part 1.

Description:

Week 6 delves into the fundamental principles of Design for Manufacturability and Assembly
(DFMA), a critical aspect of product development aimed at optimizing design to enhance
manufacturing efficiency and effectiveness.

Participants will explore the foundational concepts of DFMA, including the integration of
manufacturability considerations into the design process to streamline production workflows,
minimize costs, and improve product quality. Through engaging lectures and practical examples,
students will gain insights into the importance of early-stage design optimization and the key
principles guiding DFMA implementation.

The session will highlight strategies for simplifying product designs, reducing manufacturing
complexity, and minimizing the number of parts and assembly steps required for production.
Participants will learn how to identify and address design features that may hinder manufacturability,
such as tight tolerances, complex geometries, or material constraints.

Moreover, the session will emphasize the significance of collaboration between design engineers and
manufacturing teams to ensure seamless integration of DFMA principles throughout the product
development lifecycle. By adopting a holistic approach to design optimization, participants will
discover how DFMA can drive innovation, enhance product performance, and accelerate time-to-
market while minimizing manufacturing costs and risks.

Overall, Week 6 sets the stage for participants to embrace the principles of DFMA as an integral part
of their product design toolkit, empowering them to create designs that are not only innovative and
functional but also practical and cost-effective to manufacture.
Week 7: Advanced DFMA Techniques

Topic Covered: DFMA - Part 2.

Description:

Week 7 builds upon the foundational principles introduced in Week 6 by delving into advanced
Design for Manufacturability and Assembly (DFMA) techniques aimed at optimizing manufacturing
processes and minimizing production costs.

Participants will explore advanced DFMA methodologies and tools designed to streamline
manufacturing workflows, enhance product quality, and reduce time-to-market. Through interactive
sessions and case studies, students will gain insights into the application of DFMA principles in
complex design scenarios, including multi-component assemblies and high-volume production
environments.

The session will cover advanced DFMA tools and software solutions that enable engineers to analyze
and optimize product designs for manufacturability and assembly efficiency. Participants will learn
how to leverage DFMA software to identify potential design improvements, simulate manufacturing
processes, and quantify cost savings opportunities.

Moreover, the session will focus on best practices for integrating DFMA considerations into the
product development lifecycle, from initial design concept to final production. Participants will
explore strategies for collaborating effectively across cross-functional teams, incorporating feedback
from manufacturing and supply chain stakeholders, and iterating on design iterations to achieve
optimal results.

By mastering advanced DFMA techniques, participants will be equipped with the knowledge and
skills to drive innovation, improve product performance, and achieve competitive advantage through
optimized manufacturing processes and cost-effective design solutions.
Week 8: Introduction to Casting Processes

Topic Covered: Introduction to Casting Process - Part 1

Description:

Week 8 provides an introduction to casting processes, a fundamental method in manufacturing

The session will begin with an overview of casting as a manufacturing process, highlighting its
significance in producing complex shapes and intricate components with high dimensional accuracy.
Participants will learn about the different types of casting methods, focusing primarily on sand casting
and investment casting techniques.

Sand casting, one of the oldest and most versatile casting processes, involves the use of sand molds
to create metal components. Participants will gain insights into the sand casting process, including
pattern preparation, mold cavity creation, metal pouring, and finishing operations. Through
illustrations and demonstrations, students will understand the advantages, limitations, and
applications of sand casting in various industries.

Investment casting, also known as lost-wax casting, offers precision and intricacy in manufacturing
components with complex geometries. Participants will explore the investment casting process, from
pattern creation and mold assembly to shell building, dewaxing, metal pouring, and finishing.
Through case studies and examples, students will analyze the suitability of investment casting for
producing high-quality, dimensionally accurate parts in industries such as aerospace, automotive, and
jewelry manufacturing.

By the end of the session, participants will have a solid understanding of the principles and
applications of casting processes, laying the foundation for further exploration into advanced casting
techniques and their integration into product design and manufacturing strategies.
Week 9: Advanced Casting Techniques

Topic Covered: Introduction to Casting Process - Part 2

Description:

Week 9 delves deeper into casting processes, focusing on advanced techniques such as die casting
and permanent mold casting. Participants will explore these advanced casting methods, emphasizing
process optimization and quality control measures to enhance productivity and product quality.

Die casting is a high-speed, high-pressure casting process used to produce intricate, dimensionally
accurate components with excellent surface finish. Participants will learn about the die casting
process, including mold design, metal injection, solidification, and ejection. Through case studies and
practical examples, students will understand the advantages of die casting in mass production
applications, such as automotive and consumer electronics industries.

Permanent mold casting, also known as gravity die casting, offers advantages in terms of dimensional
accuracy and surface finish compared to sand casting. Participants will examine the permanent mold
casting process, from mold preparation and metal pouring to solidification and part removal.
Attention will be given to mold materials, gating systems, and process parameters to optimize casting
quality and productivity.

Throughout the session, emphasis will be placed on quality control measures and defect prevention
strategies in advanced casting techniques. Participants will explore methods for identifying and
addressing common casting defects such as porosity, shrinkage, and surface imperfections. By
understanding the principles of process optimization and quality assurance, students will be equipped
to implement efficient and reliable casting processes in industrial applications.
Week 10: Forging Processes and Applications

Topic Covered: Forging Processes.

Description: Week 10 focuses on forging processes and their applications in industrial manufacturing.
Participants will explore the principles and techniques involved in forging, including both open-die
forging and closed-die forging methods.

Open-die forging, also known as free forging, involves deforming metal between flat dies or anvils
to achieve the desired shape. Participants will learn about the open-die forging process, from heating
the metal to forging it into shape using hammers or presses. Through demonstrations and case studies,
students will understand the advantages of open-die forging in producing large, custom-shaped
components with improved mechanical properties.

Closed-die forging, also referred to as impression forging, utilizes shaped dies to confine and shape
the metal into the desired form. Participants will explore the closed-die forging process, including die
design, preheating of metal billets, and the forging sequence. Attention will be given to factors
influencing material flow, grain structure, and mechanical properties in closed-die forging operations.

Additionally, the session will cover the applications of forging processes in various industries,
including automotive, aerospace, and energy sectors. Participants will examine real-world examples
of forged components and their role in enhancing product performance, reliability, and cost-
effectiveness.

By the end of the week, participants will have a comprehensive understanding of forging processes
and their applications, empowering them to make informed decisions in product design and
manufacturing.
Week 11: Further Insights into Forging

Topic Covered: Introduction of Forging.

Description:

Week 11 delves deeper into the world of forging, focusing on advanced techniques and applications
in industrial manufacturing. Participants will explore the principles, processes, and applications of
forging, with a particular emphasis on both cold forging and hot forging methods.

Cold forging, also known as cold forming, involves deforming metal at room temperature or slightly
above to produce components with high dimensional accuracy and surface finish. Participants will
learn about the cold forging process, including material selection, lubrication techniques, and tool
design considerations. Through case studies and practical demonstrations, students will gain insights
into the advantages of cold forging in producing complex-shaped components with minimal material
waste.

Hot forging, on the other hand, involves deforming metal at elevated temperatures to enhance
formability and reduce forging forces. Participants will explore the hot forging process, including
heating methods, die design, and temperature control measures. Attention will be given to the
metallurgical changes that occur during hot forging, leading to improved mechanical properties and
grain structure in forged components.

Furthermore, the session will cover the applications of cold and hot forging techniques across diverse
industries, including automotive, aerospace, and construction sectors. Participants will analyze real-
world examples of forged components and their role in optimizing product performance, durability,
and cost-efficiency.

By the end of the week, participants will have gained comprehensive insights into advanced forging
techniques and their applications, equipping them with the knowledge to leverage forging processes
effectively in product design and manufacturing.
Week 12: Sheet Metal Fabrication

Topic Covered: Sheet Metal Process

Description:

Week 12 focuses on the fundamental principles and techniques involved in sheet metal fabrication, a
critical aspect of modern manufacturing processes. Participants will explore various aspects of sheet
metal processing, including cutting, bending, forming, and joining techniques, along with their
applications across diverse industries.

The session begins with an overview of the properties and characteristics of sheet metal materials
commonly used in fabrication, such as steel, aluminum, and stainless steel. Participants will learn
about material selection considerations based on factors such as strength, ductility, and corrosion
resistance, ensuring optimal performance and durability of fabricated components.

Next, the session delves into cutting techniques used in sheet metal fabrication, including shearing,
punching, laser cutting, and waterjet cutting methods. Participants will gain insights into the
advantages and limitations of each cutting method, along with factors influencing process selection,
such as material thickness, geometry complexity, and production volume.

Subsequently, the focus shifts to bending and forming operations, essential processes for shaping
sheet metal into desired geometries. Participants will learn about bending principles, tooling
requirements, and techniques for achieving precise bend angles and tolerances. Additionally, the
session covers various forming methods, including stamping, deep drawing, and roll forming, along
with considerations for material flow, springback, and forming defects.

The session also addresses joining techniques used in sheet metal fabrication, such as welding,
riveting, and adhesive bonding, emphasizing factors like joint strength, corrosion resistance, and
assembly efficiency. Through case studies and practical demonstrations, participants will gain
insights into the selection of appropriate joining methods based on application requirements and
material compatibility.

By the end of the week, participants will have a comprehensive understanding of sheet metal
fabrication processes and their applications across industries, enabling them to design and
manufacture sheet metal components efficiently and cost-effectively.
Week 13: 3D Modeling for Product Design

Topic Covered: Casting Components - 3D Modeling.

Description:

In Week 13, participants will delve into the realm of 3D modeling specifically tailored for casting
components, a crucial aspect of modern product design and development processes. This session
focuses on leveraging advanced software tools such as SolidWorks or AutoCAD to create detailed
digital models of components intended for casting processes.

The session begins with an overview of casting processes and their unique requirements for
component design. Participants will gain insights into the characteristics of casting materials, such as
metal alloys or polymers, and understand how these properties influence the design process. Emphasis
will be placed on considerations such as draft angles, fillets, and parting lines to facilitate the casting
process and minimize defects.

Next, participants will be introduced to the principles and techniques of 3D modeling, utilizing
industry-standard software platforms. Through interactive demonstrations and hands-on exercises,
participants will learn how to create accurate and detailed digital representations of casting
components, incorporating geometric features, surface finishes, and dimensional tolerances.

The session will cover essential modeling tools and commands for creating complex geometries
commonly encountered in casting applications, such as intricate part geometries, undercuts, and
internal features. Participants will also explore techniques for optimizing designs for
manufacturability, ensuring that the digital models are compatible with casting processes and capable
of producing high-quality components.

Throughout the session, participants will engage in practical exercises and case studies to reinforce
their understanding of 3D modeling concepts and their application to casting component design. By
the end of the week, participants will have acquired the skills and knowledge necessary to create
robust and manufacturable 3D models of casting components, laying the foundation for effective
product design and development in the casting industry.
Week 14: Advanced 3D Modeling Techniques

Topic Covered: Sheet Metal Components - 3D Modeling.

Description:

In Week 14, participants will embark on an exploration of advanced 3D modeling techniques tailored
for sheet metal components, an integral aspect of modern product design and manufacturing
processes. This session delves into the intricacies of creating detailed digital models of sheet metal
parts using industry-standard software tools like SolidWorks or Autodesk Inventor.

The session commences with an overview of sheet metal fabrication processes and their unique
requirements for component design. Participants will gain insights into the characteristics of sheet
metal materials, such as thickness, bend allowances, and material properties, and understand how
these factors influence the design process. Emphasis will be placed on incorporating design features
such as bends, flanges, and reliefs to achieve the desired form and function of sheet metal
components.

Next, participants will be introduced to advanced 3D modeling techniques specific to sheet metal
design. Through interactive demonstrations and hands-on exercises, participants will learn how to
leverage specialized modeling tools and commands to create complex geometries commonly
encountered in sheet metal applications. Topics covered include creating parametric models of sheet
metal parts, defining bend profiles, and incorporating features such as stiffening ribs and lances.

Throughout the session, participants will explore strategies for optimizing sheet metal designs for
manufacturability and assembly, ensuring that the digital models are compatible with fabrication
processes and capable of meeting performance requirements. Practical exercises and case studies will
reinforce participants' understanding of advanced modeling concepts and their application to sheet
metal component design.

By the end of the week, participants will have acquired the skills and knowledge necessary to
proficiently create robust and manufacturable 3D models of sheet metal components, empowering
them to tackle complex design challenges and drive innovation in the field of product design and
manufacturing.
Week 15: Plastic Components Design

Topic Covered: Plastic Components - 3D Modeling.

Description:

Week 15 focuses on the intricate process of designing plastic components using advanced 3D
modeling techniques. Plastic components play a crucial role in various industries, from consumer
electronics to automotive manufacturing, and mastering their design is essential for product
innovation and development.

During this week, participants will gain a comprehensive understanding of the unique considerations
involved in designing plastic components. One of the key aspects explored is the utilization of 3D
modeling software, which enables designers to create intricate and precise digital representations of
plastic parts. Through hands-on exercises and tutorials, students will learn how to navigate these
software tools effectively, mastering features such as parametric modeling, surface modeling, and
assembly design.

Moreover, the curriculum emphasizes the importance of considering factors like draft angles, wall
thickness, and material properties when designing plastic components. Draft angles are critical for
facilitating part ejection from molds during the manufacturing process, while optimizing wall
thickness ensures structural integrity and cost-effectiveness. Participants will learn how to incorporate
these considerations into their designs to achieve optimal performance and manufacturability.

Additionally, students will explore techniques for enhancing the aesthetics and functionality of plastic
components through features such as ribs, bosses, and snap fits. By leveraging advanced modeling
capabilities, participants will discover how to create complex geometries and intricate details that
meet the requirements of specific applications.

Throughout the week, participants will engage in practical design projects and case studies, applying
their newfound knowledge to real-world design challenges. By the end of Week 15, students will
emerge with a deep understanding of plastic component design principles and the proficiency to create
innovative and manufacturable designs using 3D modeling software.
Thank You