(MDDE) – Mechanical Design Domain Engineer
(Duration: 6 Months)
(With 100% Placement Assistance)
About the Course:
IFS Academy has partnered with a leading Engineering Services company to offer the Mechanical
Design Domain Engineer (MDDE) Program, focusing on industry-specific skills essential for success
in the Mechanical Design domain. This comprehensive course integrates software expertise in
CAD/CAM/CAE with hands-on training tailored to meet the demands of the industry. Led by industry
veterans with over 20 years of experience and certified software instructors, the program ensures
students are equipped with the necessary skills to excel in the field.
Course Curriculum
Chapter 1 - Plastic Design Domain
Duration - 6 Weeks (2 Hours each day)
1. Introduction to plastic
This topic covers what is plastic? how plastics are made? why use of plastic is increasing in
almost every industry, design requirement of plastic parts, classifications of plastic.
2. Plastic properties
For any product it is very important to select a right material which can satisfy the function
and application requirement and to select the right material, material property knowledge is
very important. In this topic we will cover plastic thermal properties, mechanical properties,
electrical properties, additives, reinforcement, case studies for right material selection, etc.
3. Plastic moulding processes
This topic covers the different moulding processes like injection moulding, extrusion
moulding, blow moulding, gas assisted injection moulding, rotational moulding, compression
moulding, thermoforming, structural foam moulding, insert moulding, over-moulding process.
4. Introduction to injection moulding tool
This topic covers the injection moulding process in details including injection moulding
machine, its components, feed system, types of gates, cooling system, ejection system,
mould construction etc.
5. Sliders and lifters
Knowledge of sliders and lifters in plastic product design is very important and it is having
relation with the product structure and cost, manufacturing cost, maintenance cost as
undercut in product design requires to use sliders and lifters in the mould which will increase
the mould cost and mould complexity.
6. Plastic defects
This topic covers the plastic defects with defects introduction, its causes and remedies to
eliminate the defects.
7. Plastic post processes
This topic covers the post processes that can be done on the plastic parts as a secondary
operations and what things need to considered while performing secondary operations on
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plastic parts like machining, finishing, threading, drilling, sawing, milling, grinding, laser
cutting, painting, electroplating, vacuum metalizing, hot stamping, sublimation printing,
screen printing etc.
8. Plastic joining methods
This topic covers how we can assemble or join the plastic parts with methods like
mechanical fasteners, snap joints, hot gas welding, hot plate welding, laser welding, spin
welding, vibration welding, ultrasonic welding, electrofusion welding, induction welding,
adhesive bonding, solvent bonding, heat staking etc.
9. Class A surface & surface continuity
This topic covers what is class A surface? Why class A surface is needed? Class A surface
modelling process, surface continuities with their significance and guidelines.
10. Design guidelines of plastic part and features
This topic covers the design guidelines to design a functional and manufacturable parts, and
it includes the guidelines regarding nominal wall thickness, corrugation, ribs, boss, holes &
cut-out, how to provide draft, corner radius and fillets, living hinge, lettering on parts, plastic
bearings, plastic gears, guidelines related to assembly feature like snap, dog house, clip
tower, locator, heat stakes, fasteners, inserts, etc.
11. Structural design of plastic
This topic covers how we can design a plastic part for different structural cases like design
for bending, shear, torsion, stiffness, impact, creep, fatigue and thermal cases.
12. Moldflow analysis
This topic covers the introduction to the moldflow analysis technically including different
analysis like filling analysis, packing analysis, shrinkage and warpage analysis, core shift
analysis, overmolding analysis, etc
13. Design for manufacturing and assembly (DFMA)
This topic covers how we can design the part for manufacturing and assembly, principles of
DFMA, methodology of DFMA, benefits of DFMA, implementation of DFMA with example.
14. CAD Topics
This topic includes understanding of core, cavity, tooling direction, draft direction, draft
analysis etc. It also covers how we can make a close volume from the A surface i.e. A to B
conversion or close volume creation with uniform thickness and close volume creation with
master sections, skin foam tasks, remastering (reverse engineering), assembly feature
creation with design guidelines, power copy, etc.
15. Projects
This topic covers the discussion as well practice on CAD projects like headliner project, car
door project, console project, cad tests, etc.
Chapter 2 - Sheetmetal Design Domain
Duration: 2 Weeks (2 Hours each day)
1. Introduction to Sheetmetal & Material Selection
In this topic, we will get introduction to sheet-metal and sheet-metal properties and
materials for different applications.
2. The shearing process
In this topic, we will study shearing processes, isotropy and anisotropy.
3. The Press-Brake Operations
In this topic, we will learn about spring-back effect, K & Y Factors, Bend Allowance,
Bend Deduction and OSSB. We will study all press-brake operation and design
guidelines.
4. The stamping operations:
In this topic, we will study stamping operations like blanking, piercing, forming, deep
driving, fine blanking, slide blanking, their design considerations, tooling processes
along with Forming Limit Diagram (FLD)
5. The Roll Forming Operations
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In this topic, we will study roll forming operations, their design guidelines, applications.
6. The Spinning Operation:
In this topic, we will study the spinning operations, design guidelines and applications.
7. The Drill Press Work
In this topic, we will study drill press work operations for sheet-metal.
8. The Deburring & Abrasion
In this topic we will learn about sheet-metal finishing operations and design guidelines.
9. The Joining Operations
In this topic, we will cover all sheet-metal joining operations including welding and
riveting and their design guidelines.
10. The Heat Treatment Operations
In this topic, we will study various heat treatment operations and their design guidelines.
11. Plating & Painting
In this topic we will understand design guidelines of plating and painting operations
Chapter 3 - GD&T (Basic & Pro)
Duration: 2 Weeks (2 Hours each day)
1. Introduction to GD&T
This topic covers why we need GD&T, basic geometric characteristic symbols, modifying
symbols and introduction to Feature Control Frame (FCF)
2. GD&T – Rules, Definitions and Terms
This topic covers concepts of Feature and Feature of Size, Actual Mating Envelop, Inner and
Outer Boundary, Virtual and Resultant conditions which are critical in GD&T applications.
We also understand Rule 1 & 2 of GD&T.
3. GD&T - Modifiers
This topic covers 20+ GD&T modifying symbols and their application along with concepts of
material conditions like MMC, LMC & RFS.
4. Form Control
This topic covers form controls such as Straightness, Flatness, Circularity and Cylindricity
with their interpretation and applications.
5. Planer & Non-Planer Datums
This topic covers planer and non-planer datums, 3-2-1 principle, Datum targets , Bonus
tolerance and datum shift concepts and you gain the confidence of how to select the datums
for given application.
6. Orientation Control
This topic covers orientation controls like perpendicularity, angularity and parallelism with
their interpretation and application.
7. Location Controls
This topic covers Tolerance of Position (TOP) applied to FOS at different material conditions,
Composite and Multi-segment Feature Control Frames, Simultaneous and Separate
Requirements. This is most widely used control in engineering drawings. We will also study
concentricity and symmetry controls and their applications.
8. Profile Control
This topic covers profile control applied to line or surface elements with applications.
9. Case Studies
We will go through real time case studies of GD&T applications.
Chapter 4 - Tolerance Stack-up Analysis (WC | RSS | MRSS Methods)
Duration – 1 week (2 Hours each day)
1. Approaches to finalize tolerance values of dimensions
In this topic we will study 2 main approaches of tolerancing the dimensions.
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2. Engineering Fits
In this topic we will cover types and interpretation of engineering fits and their applications.
3. Part and Assembly Stack-up analysis
In this topic we will study how to build dimensional circuit and conduct tolerance stack-up
analysis on the part as well as assembly. We will study Worst case and Statistical methods
of tolerance stack-up analysis. We will also study Biasing and Assembly Shift concepts.
4. GD&T applications
In this section, you will study the applications and interpretation of GD&T symbols and
modifying symbols into Tolerance stack-up analysis.
5. Case Studies
In this sections we will understand many case studies of tolerance stack-up analysis.
Chapter 5 - NPD | NPI Process
Duration – 3 Weeks ( 2 Hours each day)
1. Phases of NPD | NPI Process – Overview
In this topic, we will study overview of NPD process and how it’s different from PLC.
2. Opportunity Exploration and Target Setting
In this topic, we will study tools like QFD to set the design targets. We will study, inputs,
tools techniques and outputs of teach phases.
3. Brainstorming and Concept Selection
In this topic we will study brainstorming techniques, tools and techniques and how to
select the potential concept.
4. Concept Feasibility
In this topic, we will study how to prove the concept especially in terms of DFX.
5. Design Release
In this topic, we will study how to release the design and change management process.
6. Process Development
In this topic, we will cover how design team works with other departments to develop the
released product design.
7. Product & Process Validation
In this topic, we will study how product and process validation is carried out to meet all
the requirements including regulatory requirements.
8. Lessons Learned
In this topic we will understand various ways of capturing the learnings from the designs.
9. Systematic Problem Solving
In this topic, we will understand how to solve technical problems in the design using
systematic problem solving methods like 8D and A3.
10. Patent Process
In this topic, we will understand everything about invention and patent filing process.
11. Value Engineering
In this topic, we will cover everything about VAVE approach to optimize the cost.
Chapter 6 - DFMEA (AIAG)
Duration – 1 Week (2 hours each day)
1. Failure Mode Avoidance (FMA)
In this topic we will understand basics about DFMEA and FMA process.
2. Pre-DFMEA Tools
In this topic, we will study Pre-DFMEA tools like Boundary Diagram, Interface
Matrix, Product Structure Tree (PST), Function Tree (FT), Fault Tree Analysis (FTA),
Parametric Diagram, RCL, IFRL. We will deep dive into each tool with examples.
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3. DFMEA (AIAG)
In this topic we will learn to fill each column of DFMEA form as per AIAG Manual.
Chapter 7 - PPAP (AIAG)
Duration – 1 Week ( 2 hours each day)
In this course, we will study 18 documents and records needed for product Approval
as part of PPAP as per AIAG Manual.
Chapter 8 – Basics of Engineering
Duration – 2 Week ( 2 hours each day)
In these sessions, we will revise critical engineering subjects in perspective of job
interviews.
Chapter 9 – Resume Building & LinkedIn and Interview Skills
Duration – 1 Week ( 2 hours each day)
In these sessions, you will learn to build effective resume, LinkedIn profile and
Project Portfolio and also interview skills including mock-ups
Chapter 10 – Design Projects
Duration – 3 Weeks ( 2 hours each day)
In this section, students will work on industry mock-up projects using design skills
they learned during the course.
Chapter 11: CATIA V5 Mechanical Design
Duration = 60 Hrs.
• CATIA V5 overview in Mechanical Design
• 3D Modeling, Parts, Assemblies, Sheetmetal & Surfacing
• Drafting & Detailing
• Working on Industry Domain Oriented Case Studies / Projects like:
o Creating Surfacing & Sheetmetal Parts
o Automotive Plastics Interior and Exterior Trims
o Introduction to Seating System Design
o BIW Welding / Fixture Design
o BOM Creation
o Product Design & Development
Chapter 12: Computer Aided Design using SolidWorks
Duration = 60 Hrs.
Note: Students can select Autodesk Inventor / Solid Edge Software instead of SolidWorks if
the job requirement is available on these tools.
• SolidWorks overview in Mechanical Design
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• Understanding 2D Drawings and converting them into 3D Models
• Sketch- Drafting & Detailing
• Assembly Modeling
• 3D Modeling and Drafting of Engineering Parts, Sub-Assemblies and
Assemblies
• Creating Parametric Drawings with GD&T and Engineering Calculations
• AutoCAD to SolidWorks Models
• Working on Industry Domain Oriented Case Studies / Projects like:
o SPM / Jigs & Fixtures / Machines and Equipments
o Sheetmetal / Packaging Industry / Equipment Design
o Machine Design
o Sheetmetal Design
Chapter 13: NX CAD for Design Engineers
Duration = 60 Hrs.
• CATIA V5 overview in Mechanical Design
• 3D Modeling, Parts, Assemblies, Sheetmetal & Surfacing
• Drafting & Detailing
• Working on Industry Domain Oriented Case Studies / Projects like:
o Create 2D & 3D Tooling Processes
o Tooling Designing
o BIW Welding / Fixture Design
o Automotive Plastics Interior and Exterior Trims
o BIW Welding / Fixture Design
o BOM Creation
o Product Design & Development
o GD&T
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IFS Academy, Pune
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