Engineering Design & Modelling

Module 01 : Engineering Design Process & Design Thinking For Innovation

Design :- Process to create something that has never been created.
Engineering Design :-
- Systematic, Intelligent Process in which engineers generate, evaluate and specify solutions for
devices, systems or processes satisfying user needs and specified set of constraints.
- In other words, Engineering Design is a thoughtful process for generating plans or schemes for
devices, system or processes that attain given objectives while adhering to specified constraints.
Basic Terminology :-
- Design Objective : Feature or behavior that we wish the design to have or exhibit
- Design Constraint : Limit or restriction on the features or behaviors of the design. A proposed design
is unacceptable of these limits are violated.
- Functions : Works / Activities / Things a designed device or system is supposed to do.
- Means : Way Or Method to make a function happen.
- Form : Shape and structure of something as distinguished form its material form is central to
industrial design, a very important part of product design.
Four C’s of Design :-
 Creativity : Requires creation of something that has not existed before or has not existed in the
designer’s mind before.
 Complexity : Requires decisions on many variables and parameters
 Choice : Requires making choices between many possible solutions at all levels, from basic concepts
to the smallest detail of shape
 Compromise : Requires balancing multiple and sometimes conflicting requirements
“Design is really an act of communication, which means having a deep understanding of the person with
whom the designer is communicating”
Dieter Rams : Ten Principles For Good Design
1. Good Design is Innovative:
 Engineering should strive for innovation, bringing new ideas, technologies, and approaches
to solve problems.
 Innovation can lead to breakthroughs in efficiency, performance, and user experience.
2. Good Design Makes a Product Useful:
 Engineers should focus on creating products that serve a clear purpose and fulfill user needs
effectively.
 Utility should be a primary consideration in the design process, ensuring that the product
solves real problems for users.
3. Good Design is Aesthetic:
 Engineering solutions should not only be functional but also visually appealing.
  Attention to aesthetics enhances user satisfaction and contributes to the overall experience
of using a product.
4. Good Design Makes a Product Understandable:
 Engineers should strive for simplicity and clarity in design, making products easy to
understand and use.
 Clear user interfaces and intuitive operation enhance usability and reduce the learning curve
for users.
5. Good Design is Unobtrusive:
 Engineering should aim to create products that integrate seamlessly into users' lives without
imposing unnecessary complexity.
 Designs should prioritize simplicity and elegance, avoiding unnecessary features or
distractions.
6. Good Design is Honest:
 Engineers should be transparent and truthful in their designs, avoiding deception or
misleading representations.
 Products should accurately represent their functionality and performance to users.
7. Good Design is Long-lasting:
 Engineering should prioritize durability, reliability, and sustainability in product design.
 Long-lasting designs reduce waste and environmental impact while providing value to users
over time.
8. Good Design is Thorough Down to the Last Detail:
 Engineers should pay attention to every aspect of design, from the overall architecture to the
smallest components and interactions.
 Attention to detail ensures quality and consistency throughout the product.
9. Good Design is Environmentally Friendly:
 Engineering should consider the environmental impact of products throughout their lifecycle,
from raw materials to disposal.
 Sustainable design practices reduce resource consumption, pollution, and waste,
contributing to a healthier planet.
10. Good Design is as Little Design as Possible:
 Engineers should strive for simplicity and minimalism, removing unnecessary elements and
complexity from designs.
 Simplified designs are easier to understand, use, and maintain, leading to better overall user
experiences.
Types Of Design :-
Original Design or Innovative Design:
 - This type of design involves creating something entirely new, often pioneering novel solutions to
existing problems or addressing unmet needs.
- It focuses on creativity, imagination, and pushing the boundaries of conventional thinking.
- Examples include inventing a new product, developing groundbreaking technology, or introducing a
revolutionary design concept.
Adaptive Design:
- Adaptive design refers to modifying
existing designs to accommodate
changing circumstances or
requirements.
- It involves making adjustments or
alterations to an existing product,
service, or system to improve its
performance, usability, or relevance.
- Examples include updating software
applications to work on new
operating systems or redesigning a
website to be mobile-friendly.

Redesign:
- Redesign involves overhauling or reimagining an existing
design to enhance its functionality, aesthetics, or user
experience.
- It may involve updating outdated elements, addressing user
feedback, or incorporating new technologies or materials.
- Examples include redesigning a product packaging to be more
eco-friendly or revamping a user interface to be more
intuitive.
Selection Design:
- Selection design involves choosing or selecting from existing design options rather than creating
something entirely new.
- It may involve evaluating and comparing different design alternatives based on criteria such as cost,
performance, or aesthetics.
- Examples include selecting furniture for interior design projects or choosing components for
engineering systems from a catalog of available options.
Industrial Design:
- Industrial design focuses on designing mass-produced products for manufacturing.
- It integrates aesthetics, usability, and functionality to create products that meet user needs and
market demands.
- Examples include designing consumer electronics, household appliances, automotive interiors, and
furniture.
The Engineering Design Process :-
- Identify the Problem or Need:
o The first step is to clearly define the problem or need that the design process aims to
address.
o This involves gathering information, conducting research, and understanding the
requirements and constraints of the project.
- Define Design Criteria and Constraints:
o Establish criteria that the solution must meet, such as performance objectives, safety
standards, cost limitations, and regulatory requirements.
o Identify constraints that may influence the design process, such as time constraints,
available resources, and technical limitations.
- Generate Concepts:
o Brainstorm and explore various concepts and ideas for potential solutions.
o Encourage creativity and collaboration to generate a range of possible approaches to solving
the problem.
- Develop and Evaluate Designs:
o Select promising concepts and develop detailed designs for evaluation.
o Use analysis tools, simulations, and prototypes to assess the performance, feasibility, and
practicality of each design option.
o Evaluate designs against established criteria and constraints to determine their strengths,
weaknesses, and trade-offs.
- Refine and Optimize Designs:
o Based on evaluation feedback, refine and iterate on the designs to improve performance,
efficiency, and effectiveness.
o Incorporate feedback from stakeholders, end-users, and technical experts to address
concerns and optimize the design.
- Implement the Solution:
o Once a final design is selected, proceed with implementing the solution.
 o This may involve manufacturing prototypes, building prototypes, or developing software,
depending on the nature of the project.
- Test and Validate:
o Conduct rigorous testing and validation to ensure that the solution meets the intended
requirements and performs as expected.
o Test prototypes under various conditions, simulate real-world scenarios, and gather
feedback from users to validate the design.
- Communicate and Document:
o Document the design process, including decisions made, iterations, test results, and final
specifications.
o Communicate the design solution effectively to stakeholders, clients, and end-users through
reports, presentations, and documentation.
- Iterate and Improve:
o The design process is often iterative, with opportunities for continuous improvement.
o Gather feedback from implementation and use to identify areas for refinement and
enhancement, leading to iterative cycles of redesign and improvement.
Product Development Process : 6 Stages
- Idea Generation:
o Objective: Generate new product ideas or concepts.
o Activities: Brainstorming sessions, market research, customer surveys, and trend analysis to
identify potential opportunities and needs.
- Concept Development and Screening:
o Objective: Develop and evaluate product concepts.
o Activities: Refine initial ideas into feasible concepts, create prototypes or mock-ups, conduct
concept testing, and screen concepts based on criteria such as technical feasibility, market
potential, and alignment with company goals.
- Design and Engineering:
o Objective: Design and engineer the product.
o Activities: Detailed design, engineering analysis, prototyping, testing, and iteration to refine
the product design and ensure it meets performance, quality, and regulatory requirements.
- Prototype Development and Testing:
o Objective: Build and test prototypes to validate design concepts.
o Activities: Build physical prototypes or functional prototypes, conduct testing to evaluate
performance, usability, and safety, and gather feedback for further refinement.
- Product Launch:
o Objective: Introduce the product to the market.
o Activities: Develop marketing and sales strategies, finalize production processes, establish
distribution channels, create promotional materials, and launch the product to customers.
- Commercialization and Post-launch Evaluation:
o Objective: Commercialize the product and evaluate its performance post-launch.
o Activities: Ramp up production, monitor sales and customer feedback, gather data on
product performance and market acceptance, make necessary adjustments or
improvements, and plan for product lifecycle management.
Proble Formulation :
- Understanding any problem thoroughly is crucial to reaching an outstanding solution.
- In product design the ultimate test of a solution is meeting management’s goal in the marketplace, so it
is vital to work hard to understand and provide what it is that the customer wants.
1. Identifying Customer Needs :
- Preliminary Research On Customer Needs : Initial work may be done by a marketing department
specialist or a team made up of marketing & design professionals
- Gathering Information From Customers :
o Interviews with Customers:
 Description: Active engagement of marketing and sales teams with current and
potential customers.
 Purpose: Gather firsthand insights, preferences, and pain points from customers.
 Approach: Regular meetings, site visits, and personalized interactions.
o Focus Groups:
 Description: Moderated discussions involving 6 to 12 targeted customers.
 Purpose: Delve deeper into customer perceptions, opinions, and experiences
regarding the product.
 Approach: Facilitated sessions with prepared questions to guide discussions on
product merits and drawbacks.
o Customer Complaints:
 Description: Feedback obtained from customer grievances and issues.
 Purpose: Identify areas for product improvement and address customer concerns.
 Sources: Recorded through various communication channels such as telephone,
email, letters, or third-party websites.
o Warranty Data:
 Description: Insights gathered from product service centers and warranty
departments.
 Purpose: Assess product quality and pinpoint potential design defects through
statistics on warranty claims.
 Usefulness: Rich data source for understanding product performance and
identifying areas for enhancement.
o Customer Surveys:
  Description: Collection of feedback through written questionnaires.
 Purpose: Gain opinions on product redesign, prioritize issues, and assess the
effectiveness of implemented solutions.
 Conduct: Surveys administered via mail, email, telephone, or in-person
interactions.
Importance of Customer Feedback
- Customer feedback serves as a valuable source of information for understanding market needs
and preferences.
- Incorporating customer insights into the product development process enhances product quality,
satisfaction, and market competitiveness.
- Regular feedback mechanisms ensure continuous improvement and alignment with customer
expectations throughout the product lifecycle.
Customer Needs and Dimensions of Product Quality
1. Performance:
- Primary operating characteristics of a product, quantifiable and measurable.
- Determines how well the product fulfills its intended functions.
2. Features:
- Supplementary characteristics that enhance the basic functions of the product.
- Customizable to cater to different customer preferences and tastes.
3. Reliability:
- Probability of product failure or malfunction within a specified timeframe.
- Reflects the consistency and dependability of the product's performance.
4. Durability:
- Measure of product lifespan and resistance to wear and tear.
- Indicates how long the product can be used before replacement is necessary.
5. Serviceability:
- Ease and efficiency of product repair and maintenance after breakdown.
- Factors include repair time, cost, and availability of competent repair services.
6. Conformance:
- Alignment of product design and operating characteristics with customer expectations and
industry standards.
- Interrelated with performance and features; sets baseline for product quality.
7. Aesthetics:
- Subjective perception of how the product looks, feels, sounds, etc.
- Influences by personal judgment and individual preferences.
8. Perceived Quality:
- Association of product quality with brand reputation and previous product experiences.
- Influenced by advertising but primarily based on past product performance.
Classifying Customer Requirements
Expecter’s:
- Basic attributes expected in the product; often used in benchmarking.
Spoken’s:
- Specific features explicitly requested by customers.
Unspoken’s:
- Implicit product attributes not verbally expressed by customers but still important.
- Requires skill to identify and address effectively.
Exciters:
- Unique product features that distinguish it from competitors.
- Not essential for customer satisfaction but contribute to delighting customers.
Concept Generation Process :-
- The concept generation process is a crucial phase in product development where innovative ideas
and solutions are generated to address customer needs and preferences.
Problem Definition:
- Clearly define the problem or opportunity that the product aims to solve or capitalize on.
- Understand customer needs, market trends, and technical constraints.
Idea Generation:
- Brainstorming sessions: Encourage creative thinking to generate a wide range of ideas.
- Mind mapping: Visualize connections between different ideas and concepts.
- Analogous thinking: Draw inspiration from unrelated industries or fields.
- SCAMPER technique: Stimulate idea generation by questioning and modifying existing concepts
(Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, Reverse).
Research and Inspiration:
- Conduct market research to identify trends, competitors' products, and customer preferences.
- Seek inspiration from nature, art, technology, and other sources to spark creative ideas.
Prototyping and Visualization:
- Create rough prototypes, sketches, or mock-ups to visualize concepts and explore their feasibility.
- Use rapid prototyping tools and technologies to quickly iterate and refine ideas.
Cross-disciplinary Collaboration:
- Collaborate with team members from diverse backgrounds, including designers, engineers,
marketers, and end-users.
- Encourage open communication and idea sharing to leverage different perspectives and expertise.
Evaluation and Selection:
- Evaluate generated concepts based on predefined criteria such as feasibility, market potential,
customer value, and alignment with strategic goals.
 - Use techniques like concept scoring, SWOT analysis, and decision matrices to prioritize and select
promising concepts for further development.
Iterative Refinement:
- Iterate on selected concepts through feedback loops, user testing, and continuous improvement.
- Refine concepts based on insights gathered during prototyping, testing, and evaluation stages.
Documentation and Documentation:
- Document all generated concepts, including sketches, notes, and evaluation criteria.
- Maintain a record of the concept generation process for future reference and intellectual property
protection.

Major Concept Generation Techniques :-

- Brainstorming:
o A group creativity technique where participants generate ideas spontaneously and without
judgment.
o Encourages free-flowing and diverse thinking to explore a wide range of possibilities.
- Mind Mapping:
o Visual brainstorming technique that organizes ideas hierarchically around a central theme or
problem.
o Facilitates the exploration of connections and relationships between different concepts.
- SCAMPER:
o Acronym for Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, and Reverse.
o A structured approach to generating new ideas by systematically manipulating existing
concepts.
- Storyboarding:
o Visual storytelling technique where ideas are presented sequentially through a series of
sketches or images.
o Helps visualize user experiences, product interactions, and scenarios.
- Reverse Engineering:
o Analytical technique where existing products or solutions are deconstructed to understand
their underlying principles and mechanisms.
o Inspires new ideas by identifying opportunities for improvement or innovation.
- Analogy and Metaphor:
o Drawing parallels between unrelated concepts, industries, or domains to spark new ideas.
o Encourages lateral thinking and creative problem-solving.
- Provocation:
o Intentionally introducing provocative or challenging statements or questions to stimulate
unconventional thinking.
 o Encourages participants to question assumptions and explore alternative perspectives.
- TRIZ (Theory of Inventive Problem Solving):
o Systematic problem-solving methodology based on patterns of invention found in thousands
of patents.
o Provides a structured approach to overcoming technical contradictions and generating
innovative solutions.
- Random Stimuli:
o Introducing random or unrelated stimuli such as images, objects, or words to trigger novel
associations and ideas.
o Helps break cognitive patterns and foster creativity.
- Provocation:
o Intentionally introducing provocative or challenging statements or questions to stimulate
unconventional thinking.
o Encourages participants to question assumptions and explore alternative perspectives.
- Prototyping:
o Developing preliminary models or representations of a product or idea to explore its
feasibility, functionality, and design.
o Helps visualize concepts, test hypotheses, and gather feedback from stakeholders.
- Pilot Testing:
o Conducting small-scale trials or experiments to evaluate the performance, usability, and
acceptance of a product or service.
o Provides insights into potential challenges, improvements, and market readiness before full-
scale implementation.
Survey:
o Gathering data and opinions from a sample population through structured questionnaires or
interviews.
o Helps understand customer preferences, needs, and behaviors to inform product
development decisions.
Ideation:
o Systematically generating and exploring a wide range of ideas and concepts to address a
specific problem or opportunity.
o Encourages creativity, divergent thinking, and collaboration among team members.

Axiomatic Design:
o Engineering design methodology that emphasizes the systematic identification and
elimination of sources of variation to achieve desired system outcomes.
o Focuses on creating robust, adaptable, and efficient design solutions based on fundamental
principles.
Stimulation:
o Engaging in activities or exercises that stimulate creativity, imagination, and problem-solving
skills.
o Includes techniques such as brainstorming, mind mapping, and role-playing to inspire new
ideas and perspectives.
Project Planning & Management
 - Project manager is responsible for creating, tracking, and revising the plan.
- The process of planning should include multiple groups and people, typically called stakeholders, or
sometimes the audience
- Planning Process Includes :-
o Breaking the project into set of tasks
o Developing a list of approvals and milestones
o Itemizing required resources
o Checking the plan for consistency
- The plan often includes a schedule for tasks and time, a budget for money and a communication
list.

Key Elements of Successful Project Planning :-

- Clear Objectives: Define what needs to be achieved and what's out of scope.
- Stakeholder Engagement: Involve sponsors, clients, team members, and users early on.
- Resource Allocation: Ensure efficient distribution of human, financial, and material resources.
- Time Management: Create a realistic timeline with milestones and deadlines.
- Risk Management: Identify and mitigate potential risks with contingency plans.
- Budget Planning: Establish and monitor expenses to stay within budget.
- Quality Assurance: Set standards and metrics to meet stakeholder requirements.
- Communication Plan: Regularly update stakeholders on progress and issues.
- Change Management: Anticipate and manage changes effectively.
- Monitoring and Evaluation: Continuously assess project performance.
- Documentation: Maintain thorough records of plans, reports, and meetings.
- Team Collaboration: Foster a supportive and motivated team environment under effective
leadership.
Human Centered Design (HCD) :
- Creative approach to problem-solving that starts with people and ends with innovative solutions
that are tailor-made to suit their needs.
Human-Centered Design (HCD) Process:
- Observation:
 o Observe end-users and understand their needs and challenges.
o Identify patterns of behavior and pain points to find opportunities.
- Ideation:
o Brainstorm ideas based on observations and user experiences.
o Focus on meeting the needs and desires of the users.
- Rapid Prototyping:
o Build a simple prototype quickly to make the solution tangible.
o Use materials like cardboard for simplicity and ease of testing.
- User Feedback:
o Gather feedback from end-users by testing the prototype.
o Critical phase for ensuring the solution meets user needs and expectations.
- Iteration:
o Use feedback to make necessary changes and improvements to the design.
o Continuously iterate, test, and integrate user feedback until the solution is refined.
- Implementation:
o Validate the solution's usefulness with end-users.
o Prepare for deployment or launch.
o Repeat the process for future updates, always incorporating user feedback.

Design Thinking: -
- Design thinking and human-centered design (HCD) share common principles and objectives, but
they also have distinct differences.
- While both approaches prioritize understanding and addressing user needs, design thinking extends
beyond traditional HCD methodologies in several ways:
1. Problem-Solving Focus: Design thinking expands problem-solving beyond design, encouraging
diverse collaboration.
2. Iterative Process: Rapid cycles of ideation, prototyping, and testing enable quick adaptation to user
feedback.
3. Empathy and Human-Centricity: Design thinking incorporates techniques like empathy mapping for
deeper user understanding.
4. Creative Confidence: Encourages creativity and risk-taking for innovative solutions.
5. Scale and Scope: Applicable to diverse fields beyond traditional design challenges.
1 approach – 2 names?
- Both "human-centered design" and "design thinking" prioritize putting humans at the core of
product development.
- This includes considering the needs of users and other stakeholders throughout the entire process,
from understanding the context of use to evaluation.
Iterative Approach:
- Both approaches employ an iterative process. While human-centered design follows phases such as
understanding context, specifying user requirements, producing designs, and evaluation, design
thinking divides the process into six phases.
- Despite the formal distinctions, the iterative nature remains a common feature.
Human-Centered Design:
 1. Focuses on placing humans at the center of product development.
2. Follows an iterative process with phases like understanding context and evaluating solutions.
3. Primarily used for design challenges but adaptable to various fields.
4. Encourages creativity and risk-taking within design contexts.
5. Utilizes techniques like empathy mapping for deeper user understanding.
Design Thinking:
1. Emphasizes problem-solving beyond design, encouraging multidisciplinary collaboration.
2. Utilizes an iterative process, formally divided into six phases.
3. Applicable to diverse challenges beyond design, including business strategy and social innovation.
4. Fosters creative confidence and embraces experimentation across different domains.
5. Incorporates techniques like empathy mapping and brainstorming sessions for generating
innovative solutions.
Aspect Human-Centered Design Design Thinking

Puts humans at the core of product

Emphasizes multidisciplinary problem-solving,
Focus development, considering user and
extending beyond design challenges.
stakeholder needs.

Follows iterative process, repeating phases Utilizes an iterative process, formally divided into six
Iterative
like understanding context and evaluating phases, with similarities to human-centered design's
Approach
solutions. approach.

Starting Point Analyzes user tasks, characteristics, and Utilizes methods like personas and prototypes to
Analysis environment to meet all requirements. understand user needs and gather feedback.

Focuses on developing innovative solutions for

Aims for highly usable products with great
Special Focus complex issues, ensuring technical feasibility and cost-
user experience.
effectiveness.

Primarily for product development, adaptable Broader scope, applicable to social questions and
Scope of Use
to various fields. fostering innovation.

Emphasis Focuses on user needs and experience. Emphasizes innovation and creativity.
Design Thinking – New Old Creativity
 Revolutionizing Human-Centered Design?
 Design thinking, an up-and-coming trend, developed by Stanford University Professors and
brought to Europe by SAP co-founder Hasso Plattner.
 Increasing adoption by companies for developing user-centric products and services.
 Human-centered design (HCD) since the 1990s emphasizes continuous user orientation.
 Common Features:
 Both prioritize humans at the center of product development, considering user and
stakeholder needs.
 Employ an iterative approach, considering needs throughout all phases of product
development.
 Iterative Approach:
 HCD follows four phases: understanding context, specifying user requirements, producing
design solutions, and evaluation.
 Design thinking divided into six phases, with many similarities to HCD's approach.
 Analyzing the Starting Point:
 Involves analyzing user tasks, characteristics, and environment to meet all requirements.
 Utilizes similar methods like personas and prototypes for understanding user needs and
gathering feedback.
 Different Aims:
 HCD aims for highly usable products and great user experience.
 Design thinking aims at developing innovative and creative solutions for complex issues.
 Scope of Use:
 Design thinking has a broader scope, applicable beyond user interface and known issues, for
developing new products, services, and solving social questions.
 Structured vs. Flexible Approach:
 HCD is described and defined in an official standard, more structured compared to design
thinking.
 Design thinking involves a new mindset and collection of principles, methods, and
techniques, following a more flexible and creative approach.
 Cross-Disciplinary Teams:
 Design thinking emphasizes working in cross-disciplinary teams, ensuring diverse
perspectives and impartial, solution-oriented approach.
 HCD, though also requiring cross-disciplinary teams, is mainly controlled by usability
professionals in practice.
Design Thinking As Mindset :
- Design Thinking as mindset is characterized by the simultaneously playful and solution-oriented
combination of these principles.
1. Innovation for Humans:
 Emphasizes human-centeredness, focusing on meeting human needs effectively.
 Rooted in the belief that innovation should serve people's needs; if not, the process must
iterate.
2. Combining Divergent and Convergent Thinking:
 Expands solution space by exploring unconventional paths through divergent thinking.
 Challenges existing frameworks and fixed conditions, leading to innovative solutions.
3. "Fail often and early":
 Encourages experimentation with numerous ideas, accepting that many will fail.
 Early testing with end customers helps identify viable solutions and facilitates rapid learning.
4. Build Experienceable Prototypes:
 Prioritizes building tangible prototypes over abstract models.
 Allows for quick testing and understanding of new ideas, diverging from traditional
development methods.
5. Test Early with Customers:
 Promotes continuous and direct engagement with end customers to gather feedback
promptly.
 Extreme customer orientation is crucial for success in Design Thinking.
6. Design Never Ends:
 Embraces iterative cycles, constantly questioning and refining solutions.
 Accumulates knowledge and experience about the problem and customer needs over time.
7. Special Place for Design Thinking:
 Requires dedicated spaces designed to facilitate collaboration and innovation.
 Equipped with materials and tools for prototyping and communication, fostering creativity
and effective teamwork.
Design Thinking As Process :
- The micro process, [also called Stanford Design Innovation
Process or at the Hasso Plattner Institute in Berlin just Design
Thinking Process is the central process of Design Thinking.
Design Thinking as Process:
1. Define the Problem:
 Formulate the problem brief, describing the problem to solve in the form of a question.
2. Need Finding & Synthesis:
 Uncover end customers' needs, distinguishing between obvious and hidden needs.
 Gain expertise through expert interviews, literature review, and web search to facilitate
meaningful discussions with customers.
3. Ideate:
 Generate solution ideas through brainstorming, ensuring solutions are aligned with
customer needs identified in previous steps.
4. Prototype:
 Build prototypes for testing with customers, varying in resolution from wood constructions to
simulated information systems.
 Central step for the success of the project, enabling validation and refinement of ideas.
5. Test & Learn:
 Testing prototypes provides insights into their effectiveness and identifies reasons for success
or failure.
 Verify whether the original problem brief addressed the needs of customers.
 If successful, begin a new micro process; if not, reformulate the challenge based on new
insights.
Design Thinking As Tool :
- Design Thinking works only when tools and methods used are aligned with this new way of thinking.
The methods and tools used in Design Thinking projects originate from very diverse areas, like
quality management, research in creativity and design, research in communication, ethnography,
and informatics
Stakeholder Map:
- Identifies internal and external groups affected by the project, ensuring comprehensive
understanding of stakeholders' perspectives.
Empathy Map:
- Analyzes talks and interviews with stakeholders, categorizing insights into "Say," "Do," "Think," and
"Feel" to understand their experiences and needs.
5-Whys Method:
- Utilizes repetitive questioning of "why" to delve deeper into the root causes of problems or
phenomena, facilitating thorough problem analysis.
AEIOU Method:
- Structures problem dimensions into "Activities," "Environment," "Interactions," "Objects," and
"Users," aiding in problem understanding and solution development.
Persona Method:
- Creates personas embodying the behavior and characteristics of user groups, facilitating empathy
and understanding of users' needs.
Observation:
- Observes stakeholders, particularly customers, to uncover both obvious and hidden needs, providing
valuable insights for problem refinement.
Storytelling:
- Presents innovative ideas or solutions effectively through compelling narratives, often using videos
to showcase prototypes in real-life situations or processes.
Empathy Map :-
- An empathy map is a collaborative tool, teams can use to gain a deeper insight into their customers.
Much like a user persona, an empathy map can represent a group of users, such as a customer
segment
Empathy Mapping Session:
1. Team Assembly:
 Gather team members and provide any relevant personas, data, or insights related to the
target of the empathy map.
2. Preparation:
 Print or sketch the empathy map template on a large piece of paper or whiteboard.
3. Distribution of Materials:
 Provide each team member with sticky notes and a marker.
4. Brainstorming:
 Encourage team members to write down their thoughts, observations, and insights on sticky
notes.
 Aim for each person to contribute to every section of the empathy map.
Empathy Map Usage:
 Empathy maps are versatile tools useful in various scenarios, including:
 Exploring customer segments in a business model.
 Developing detailed user personas.
 Understanding user behaviors during pair interviews.
 Enriching the "user" component of user stories.
Sample Questions:
 During the empathy mapping session, consider asking questions such as:
 What emotions and thoughts might
the user be experiencing? What are
their concerns and aspirations?
 What might the user's peers say while
they interact with our product? What
auditory cues might the user
encounter?
 What visual stimuli would the user
encounter in their environment while
using our product?
 How might the user behave and
communicate while using our
product?
 What are some challenges or anxieties
the user might face when using our
product?
  What potential benefits or positive experiences might the user gain from using our product?
Interviewing, Questioning & Brainstorming :-
Brainstorming Overview:
 Purpose:
 Brainstorming is a tool utilized by teams to extract ideas from each individual and present
them systematically to the entire team.
 Environment:
 The crucial element is to establish a criticism-free environment conducive to creative and
uninhibited exploration of options or solutions to a design problem.
 Benefits:
 Facilitates the liberation from outdated and ineffective ideas, allowing the team to explore
new avenues and possibilities.
 Outcome:
 This open-ended approach to idea generation may yield some initially underdeveloped
concepts, yet it has the potential to uncover novel and innovative solutions to challenges.
Specific Benefits of Brainstorming:
1. Encourages Creativity:
 Expands thinking to consider all aspects of a problem or solution, allowing the design team
to identify a wide range of options.
2. Rapid Idea Generation:
 Facilitates the rapid production of numerous ideas by encouraging participants to contribute
whatever comes to mind, enabling groups to develop many ideas quickly.
3. Equalizes Involvement:
 Provides a nonjudgmental environment where all team members are encouraged to offer
ideas, ensuring equal participation and recording of all contributions.
4. Fosters Ownership:
 Promotes a sense of ownership among team members as they actively participate in the
brainstorming process, leading to greater support for resulting decisions.
5. Input for Other Tools:
 Serves as input for other tools such as affinity diagrams and multi-voting, allowing teams to
generate ideas about various issues, causes of problems, approaches, or actions to take.
Rules for Brainstorming:
1. Active Participation:
 All team members must express their ideas, regardless of how silly or unconventional they
may seem.
2. No Discussion During Brainstorming:
  Avoid criticisms, compliments, or other comments during the brainstorming session to
maintain focus on idea generation.
3. Building on Ideas:
 Encourage participants to build on ideas generated by others to stimulate further creativity.
4. Record Ideas Exactly:
 Write down all ideas exactly as presented and display them where everyone can see them.
5. Set Time Limit:
 Establish a time limit to keep the session focused and efficient.
6. Clarify Ideas After Brainstorming:
 Review the list of ideas after the brainstorming session to ensure all team members
understand them, without making judgments about their validity.
7. Combine Similar Ideas:
 Explore whether similar ideas can be combined to streamline the list and identify common
themes.
Mind Maps :-

Mind
Mapping

Planning Creativity Productivity Collaboration Benefits

Projects Ideas More Efficient Team Work Overview

Easy To
Goals Innovation Intuitive Sharing
Memorize

Simple, Fast &

Strategies Thoughts Colleagues
Fun

Mind Mapping Overview:

 Definition:
 Mind maps are graphical representations of information that allow for the organic
brainstorming of thoughts, ideas, and keywords without the constraints of linear
structure.
 Structure:
 The central concept or main idea is positioned at the center of the map, with related ideas
branching off in various directions, creating a radiant structure.
  Benefits:
 Structuring Information: Mind maps effectively organize vast amounts of information,
displaying hierarchy, relationships, and the overall "big picture."
 Enhancing Productivity: They facilitate faster learning, more efficient communication, and
more effective brainstorming, saving significant amounts of time.
 Fostering Creativity: Mind mapping stimulates creative thinking and allows for the rapid
transcription of ideas, promoting a smooth flow of thought organization.
 Improving Memory: Visual presentation of information in mind maps, utilizing images,
colors, and connections, aids in processing and memorization. Studies indicate significant
memory improvement, particularly beneficial for students with learning difficulties.
 Five Essential Characteristics:
1. Central Image: The main idea or subject is depicted in a central image.
2. Radiating Branches: Main themes extend as branches from the central image.
3. Key Words/Images: Each branch includes a key word or image representing its theme.
4. Subtopics: Lesser important topics are represented as smaller branches or "twigs."
5. Connected Structure: The branches form a connected nodal structure, illustrating the
relationships between ideas.
Innovation Flow Chart :-
 Definition:
 The Innovation Flowchart is a detailed overview of the various stages involved in an
innovation process. It outlines the activities, requirements, and goals of each stage,
providing a structured framework for managing innovation projects or initiatives.
 Components:
 Activities: Lists the specific tasks or actions to be undertaken at each stage of the innovation
process.
 Requirements: Identifies the necessary resources, skills, people, and finances needed to
execute each stage successfully.
 Goals: Outlines the objectives or outcomes to be achieved at each stage, guiding the overall
progress of the innovation process.
 Purpose:
  Review and Organization: The structured overview provided by the Innovation Flowchart
helps teams review their progress in the innovation process and organize their next steps
effectively.
 Benefits:
 Spotting Growth Opportunities: By understanding which resources to focus on at each stage
of the process, teams can identify opportunities for growth and development.
 Ensuring Comprehensive Consideration: The flowchart prompts teams to consider all
aspects of the innovation process, ensuring that no critical factors are overlooked or
neglected.
 Implementation:
 Teams can use the Innovation Flowchart as a reference tool throughout the innovation
process, regularly revisiting it to track progress and ensure alignment with goals and
requirements.
 It can also serve as a communication tool, facilitating discussions among team members and
stakeholders regarding the various stages and requirements of the innovation process.
SCAMPER :-

Question Ladder :-
Journey Mapping :-
1. Definition: A journey map visualizes the sequential steps a person takes to accomplish a goal.
2. Creation Process: It begins with outlining user actions on a timeline, followed by incorporating
thoughts and emotions to create a narrative.
3. Interchangeable Terms: "User journey map" and "customer journey map" are often used
synonymously to represent the usage of a product or service.
4. Format Overview: Typically structured with:
 Top: Specific user or customer scenario, along with expectations or goals.
 Middle: Phases comprising user actions, thoughts, and emotions.
 Bottom: Concluding with insights, opportunities, and internal reflections.
5. Purpose: Helps understand the user experience, identify pain points, and uncover opportunities for
improvement.
6. Key Benefits: Provides a holistic view of the user journey, facilitating empathy, decision-making, and
alignment across teams.
7. Application: Used in various industries, including UX design, product development, marketing, and
customer service.
 Module 02 : Engineering Design Approaches
Professional and Societal Context of Design
1. Understanding Society: Society is a group of humans characterized by mutual interests, cultural
patterns, shared institutions, and a common identity. Technology is integral to society's functioning.
2. Role of Engineering: Engineers systematically develop and apply technology for the benefit of
society, impacting various aspects of daily life.
3. Challenges Faced:
 Effective resource utilization.
 Accessible healthcare tailored to diverse societal needs.
 Addressing issues like the youth bulge and its security implications.
Professionalism in Engineering:
1. Professional Characteristics:
 Work involves non-routine tasks requiring skills, judgment, and discretion.
 Extensive formal training is necessary for qualification.
 Specialized organizations establish standards, codes, and rules of practice.
 Commitment to serving the public good is paramount.
2. International Professional Engineering Societies/Institutes (non-legal):
 ASME (American Society of Mechanical Engineers)
 IEEE (Institute of Electrical and Electronics Engineers)
 ASCE (American Society of Civil Engineers)
 And others, which set standards and promote professional development.
Types of Design :-
Conceptual Design and Embodiment Design

1. Embodiment Design Overview:

 Also known as preliminary design or
system-level design.
 Involves further development of a
single concept or a small set of
concepts generated from the
conceptual design phase.
2. Feasibility Design Review:
 Determines whether the design concept is promising enough for further development.
 Major dimensions, components, materials, and critical-to-quality parameters are tentatively
selected and evaluated.
 3. Embodiment Design Phase:
 Gives physical form to the design concept, refining it into a tangible product.
 Involves three main activities: product architecture, configuration design, and parametric
design.
Product Architecture:
 Arrangement of physical elements to fulfill product functions.
 Emerging during conceptual design, it's finalized in the embodiment phase.
 Organized into modules, each comprising components for specific functions.
Modular vs. Integral Architecture:
 Modular: Each module serves few functions with well-defined
interactions.
 Integral: Few modules perform multiple functions, reducing
component count.
 Modular design allows for standardization and cost savings through
component reuse.
 Integral architecture suits weight, space, or cost constraints and
minimizes part count for manufacturing efficiency.
Trade-offs and Considerations:
 Integral architecture may lead to complex parts but reduces overall component count.
 Modular design accelerates development by allowing independent module development.
 Product architecture impacts manufacturing costs and development cycle length.
In summary, the embodiment design phase refines the conceptual design into a tangible product,
considering architectural choices that balance functionality, cost, and manufacturing efficiency.
Types of Modular Design:
1. Slot-modular:
 Interfaces between modules are different from
each other.
 Each module requires a distinct interface to
perform its function.
 Example: Automobile radio and DVD player
cannot be interchanged.
2. Bus-modular:
 Modules can be assembled along a common interface or bus.
 Allows for easy interchange of modules.
 Commonly used in electrical products and mechanical systems like shelving systems.
3. Sectional-modular:
 All interfaces are of the same type.
 No single element serves as an attachment point for other modules.
 Components connect to each other through identical interfaces, resembling a piping system.

Configuration Design:
- Definition: Configuration design establishes the
shape and general dimensions of components.
- Component Types: Components include special-
purpose parts, standard parts, and standard
assemblies.
- Characteristics: A part is characterized by geometric
features such as holes, slots, walls, ribs, projections,
fillets, and chamfers, including their location and
orientation.
- Examples: Four possible physical configurations for a
component (right-angle bracket) are bending from a
flat plate, machining from a solid block, welding
from three pieces, or casting.
- Types of Parts:
 Standard Part: Generic function, manufactured routinely without regard to a specific
product.
 Special-Purpose Part: Designed and manufactured for a specific purpose in a particular
product line.
- Assembly:
 Collection of two or more parts.
 Subassembly: Assembly included within another assembly or subassembly.
 Standard Assembly: Assembly or subassembly with a generic function, manufactured
routinely.
- Steps:
 Review product design specifications and specifications for the relevant subassembly.
  Establish spatial constraints for the product or subassembly (product architecture).
 Create and refine interfaces or connections between components (product architecture).
 Consider design for manufacture (DFM) principles: Determine if parts can be eliminated or
combined, and evaluate the use of standard parts or subassemblies.
- Material and Production: Configuration design depends on material availability and production
techniques. Decisions about component design rely on decisions about material selection and
manufacturing processes.
- Interrelationship: There is a close interrelationship between functions, form, material, and
production method, influencing each other in the design process.
Parametric Design:
- Definition: Parametric design optimizes specific design elements, known as variables, to enhance
both performance and manufacturability.
- Variables: Controlled attributes include dimensions, materials, shape, and manufacturing processes.
- Objective: Set variable values to achieve the best design outcome.
- Steps:
 Formulate Problem: Understand functions, identify solution parameters, define variables.
 Generate Designs: Create alternatives by adjusting variable values.
 Analyze Designs: Predict performance and identify feasible options.
 Evaluate Results: Assess designs based on parameters and select optimal solution.
 Refine/Optimize: Adjust variables for further enhancement if needed.

Codes & Standards :

 Definition: Standardization involves unifying solutions through national and international
standards, company standards, and design catalogues.
 Objectives: Standardization aims to limit solution variability without hindering the search for
multiple solutions.
 Origin: Standards come from various bodies such as national institutions (e.g., BSI, DIN), European
bodies (e.g., CEN, CENELEC), international organizations (e.g., IEC, ISO), and national bureaus (e.g.,
BIS).
  Types: Standards vary in product content, including communication, classification, planning,
dimensional, material, quality, and safety standards.
 Scope: Standards can be basic (general and interdisciplinary) or special (for specialist fields).
 Additional Sources: Besides national and international standards, engineers can refer to rules from
professional engineering institutions like ASME and IMechE, as well as internal company standards
and regulations.
Design Features :-
- Definition: Design features refer to the specific attributes, characteristics, or elements incorporated
into a product, system, or structure during the design process.
- Types: Design features can include physical attributes such as size, shape, color, texture, and
material composition. They also encompass functional aspects like usability, ergonomics,
performance, reliability, and safety.

- Purpose: Design features are implemented to fulfill specific user needs, meet functional
requirements, enhance user experience, differentiate products from competitors, and align with
design goals and objectives.
- Considerations: Designers must consider various factors when determining design features,
including user preferences, technological capabilities, regulatory requirements, cost constraints,
manufacturing feasibility, and environmental sustainability.
- Iterative Process: Design features often evolve throughout the design process, starting from
conceptualization and continuing through prototyping, testing, and refinement stages. Iterative
feedback loops and user testing help optimize design features to better meet user needs and
expectations.
- Innovation: Design features can drive innovation by introducing novel solutions, creative
functionalities, unique aesthetics, and disruptive improvements to existing products or systems.
- Adaptability: Design features should be adaptable to accommodate changes in user requirements,
market trends, technological advancements, and regulatory standards over time, ensuring long-
term relevance and competitiveness.
Aesthetic Design:
1. Definition: Focuses on visual appearance and sensory appeal.
2. Purpose: Enhances user experience through visual appeal and emotional engagement.
3. Considerations: Cultural influences, design trends, brand identity, and user preferences.
4. Impact: Influences user perception, brand image, and purchase decisions.
Difference Between Tabular Form Functional Usability & Aesthetic Usability:
Tabular Form Functional Usability:
1. Definition: Emphasizes task efficiency and effectiveness.
2. Focus: Prioritizes functionality, ease of use, and task completion.
3. Evaluation Metrics: Task success rate, time on task, error rates, and user satisfaction.
Aesthetic Usability:
 1. Definition: Integrates aesthetic principles into interface design.
2. Focus: Enhances visual appeal, engagement, and emotional connection.
3. Evaluation Metrics: Subjective measures of visual appeal and user satisfaction.
Aesthetic Design:
- Definition: Aesthetic design pertains to the philosophy of art, beauty, and taste, influencing the
creation and appreciation of beauty.
- Halo Effect: Similar to how attractive individuals are often perceived as having positive qualities
beyond appearance, aesthetically pleasing products are often assumed to possess greater value and
quality.
- Categories of Aesthetics:
 Vision: Dominated by sight, visual aesthetics encompass elements like color, shape, texture,
and balance.
 Hearing: Auditory aesthetics involve elements such as loudness, pitch, melody, and
repetition, influencing how sounds are perceived in product design.
 Touch: Material aesthetics are crucial for physical products, encompassing elements like
texture, shape, weight, and comfort, which significantly impact user experience.
 Taste and Smell: These senses contribute to deeper aesthetic experiences, especially in
industries like food and environmental design, with elements like strength, sweetness,
sourness, and texture playing key roles.
- Importance of Aesthetic Design:
 Evolution of User Expectations: Modern users expect products to offer more than just
functionality; they seek aesthetic pleasure and sensory stimulation.
 Enhanced User Experience: Aesthetic design evokes positive emotions, satisfying users'
desires for pleasurable interactions with products.
 Aesthetic Usability: Beautiful products are often perceived as easier to use and more
valuable, influencing user perceptions and behaviors, a phenomenon known as "Aesthetic
Usability."
Design for Production:
1. Relationship Between Design and Production:
 Design decisions significantly impact production costs, times, and product quality.
 Designing for production aims to minimize costs and times while ensuring product quality.
2. Appropriate Overall Layout Design:
 The overall layout determines product division into assemblies and components, derived
from the function structure.
3. Appropriate Form Design of Components:
 Designers influence production costs, times, and product quality through shape, dimensions,
surface finishes, tolerances, and fits of components.
4. Appropriate Selection of Materials and Semi-Finished Materials:
 Optimal material selection considers various factors like function, safety, production, quality
control, and costs.
5. Appropriate Use of Standard and Bought-Out Components:
  Using readily available standard or bought-out components reduces production costs and
storage requirements.
6. Appropriate Documentation:
 Production documents like CAD models, drawings, and assembly instructions significantly
impact costs, delivery dates, and product quality.
Design for Maintenance:
 Maintenance design aims to
 prevent damage
 simplify service procedures
 make inspection and repair measures easily executable.
 Avoid the possibility of errors during disassembly, reassembly and start up
 Service Measures:
 Service focuses on activities like refilling, lubricating, conserving, and cleaning.
 These tasks should be supported by ergonomic, physiological, and psychological principles,
with features like easy access and clear instructions.
 Reducing Inspection Measures:
 Inspection efforts can be minimized if the technical solution embodies direct safety
techniques, ensuring high reliability.
 Technical Measures for Maintenance:
 Prefer self-balancing and self-adjusting solutions to reduce maintenance requirements.
 Aim for simplicity and fewer parts in the design.
 Use standard components whenever possible.
 Ensure easy access to components for maintenance tasks.
 Design for easy disassembly of components when needed.
 Apply modular principles to facilitate component replacement.
 Use a minimal set of service and inspection tools to streamline maintenance processes.
 Ergonomic Guidelines:
 Service, inspection, and repair locations should be easily accessible for maintenance
personnel.
 The working environment must adhere to safety and ergonomic standards to ensure the
well-being of maintenance workers.
 Ensure visibility of components and working areas to facilitate inspection and maintenance
tasks.
 Functional processes and supporting measures should be clearly defined and easy to
understand.
 Damage localization should be possible to identify and address issues efficiently.
 Exchange of components should be straightforward, allowing for easy replacement during
maintenance activities.
 Integration with Overall Cost:
 Maintenance procedures should be compatible with the functional and operational
constraints of the technical system.
 Include maintenance costs in the overall cost assessment, along with purchase and
operating costs, to ensure comprehensive budgeting and planning.
Design for Minimum Risk:
 Despite precautions, design decisions may still leave uncertainties and evaluation gaps.
 Designers mitigate risks by providing substitute solutions based on fault analysis, ensuring reliable
products despite uncertainties.
 Balancing technical and economic hazards, designers offer valuable experiences to manufacturers
and reliable products to users.
Adequate and Optimum Design:
 Adequate Design:
 Satisfies function requirements while keeping undesirable effects within acceptable limits.
 Optimum Design:
 Selects the most suitable design from all feasible options, maximizing desired outcomes and
minimizing undesired ones.
 Objectives of Optimum Design:
 Fulfill functional requirements.
 Select the best possible option from alternatives.
 Maximize desirable effects while minimizing undesirable ones.
 Reach the best solution without repeating work.
 Usability:
 Degree of ease with which products can be used to achieve required goals effectively and
efficiently.

 User Experience (UX):

 Concerned with all aspects of the user's experience when interacting with a product, service,
environment, or facility.
 Focuses on making users happy before, during, and after using a product.
 Usability Testing:
 Common technique to evaluate interface usability.
 Provides insights from users' actions rather than their verbal feedback.
 Objectives include gaining insights, meeting user expectations, and checking if design
matches real-world use.

 Usability Testing Overview:

 Common technique to assess interface usability.
 Focuses on user actions rather than verbal feedback.
 Objectives:
 Gain insights from users.
 Assess if user expectations are met.
 Verify alignment with business decisions.
 Evaluate user task performance.
 Ensure project is on the right track.
 Obtain user reactions and feedback.
 Benefits of Usability Testing:
 Reduces the risk of building the wrong product.
 Saves money, time, and resources.
 Identifies problems early for easier and cheaper fixes.

 Steps for Usability Testing:

 Create a test plan.
 Facilitate the test.
 Analyze case data.
 Create a test report.
 Step 1: Create a Test Plan:
 Define Scope of Work:
 Decide areas to test, list comprehensively, refine.
 Limit tasks to no more than 12.
 Recruit Users:
 Key step; consider demographics or psychographics.
 Jakob Nielsen suggests 5 users per segment.
 Identify Objectives:
 Determine what to achieve, demonstrate to stakeholders.
 Establish Metrics:
 Metrics provide factual user/task performance descriptions.
 Guide design decisions with concrete usability recommendations.
 Step 2: Facilitate the Test:
 Facilitator tips:
 Encourage users to vocalize thoughts and feelings.
 Maintain a realistic test environment.
 Take structured/unstructured notes; record sessions.
 Avoid leading users; refrain from premature conclusions.
 Test objectives:
 Seek quantitative data (time on tasks, success/failure rates) and qualitative insights
(stress responses, satisfaction).
 Prototype considerations:
 Can be lo-fi or hi-fi wireframes based on defined objectives.
 Prototype Considerations:
  Determine the appropriate fidelity of prototypes based on the specific goals of the
usability test.
 Lo-fi wireframes or hi-fi prototypes can be used based on the complexity of the tasks
being tested and the desired level of realism.
 Step 3: Analyze Case Data:
 Examine trends, note potential issues and solutions.
 Review all collected data to identify patterns, trends, and potential usability issues.
 Note any recurring themes or challenges observed across multiple user sessions.
 Document findings systematically to facilitate further analysis and interpretation.
 Step 4: Create Test Report:
 Components:
 Background summary, methodology, test results, findings, and recommendations.
 Purpose:
 Not to validate decisions but to understand user perception and usage.
 Cost-effective, saves development time, and resources.

Customer Co Creation :-
 Customer co-creation involves collaborating with external parties like customers, stakeholders, and
online communities.
 Goal: Leverage diverse perspectives to enhance product development or creative processes.
 Methods: Co-designing, co-developing, and co-evaluating products or services.
 Benefits: Improved product relevance, increased satisfaction, enhanced brand loyalty.
 Tools: Idea workshops, crowdsourcing, online forums for feedback.
 Enhances innovation by integrating customer insights into the design process.
 Module 03 : Sustainable Design & Communication
Sustainable Design :-
- Sustainable design seeks to reduce negative impacts on the environment.
- Sustainable design acts as a philosophy that is applied by different companies, governmental
entities, and nongovernmental organizations to achieve a better future for the human race
through the wise and low-volume consumption of Earth’s resources.
Principle Of Sustainable Design :-
- Form:
o Visual Shape of the Product: Focuses on designing products with aesthetically pleasing and
functional forms.
o Energy Efficiency: Emphasizes designing products to minimize energy consumption during
production, packaging, and transportation, thereby reducing environmental impact and
costs.
- Function & Usability:
o Efficient Use: Aims to design products that allow consumers to use them efficiently, saving
time and energy.
o Waste Reduction: Seeks to minimize waste and throwaways associated with the product's
usage, promoting sustainability throughout its lifecycle.
- Cost-Effective Solution:
o Affordability: Strives to reduce the cost of sustainable products, making them more
accessible and economically viable for consumers.
- Renewable Energy:
o Alternative Energy Sources: Advocates for the use of renewable energy sources such as solar
or wind energy in the production and operation of products, reducing reliance on carbon-
based energy sources and mitigating climate change impacts.
- Durable Design Solutions:
o Waste Reduction: Aims to achieve zero waste by designing products with durability and
longevity, reducing the need for frequent replacements and disposal.
o Resource Conservation: Seeks to decrease dependence on Earth's finite resources by
promoting sustainable materials and manufacturing processes.
- Design for Reuse and Recycling:
o Extended Lifecycle: Focuses on designing products with the potential for reuse or recycling
at the end of their lifecycle, minimizing environmental impact and promoting circular
economy principles.
o Resource Recovery: Encourages the recovery and reuse of materials from discarded
products, reducing the demand for virgin resources and minimizing waste generation.
- Bio-mimicry:
o Natural Inspiration: Involves redesigning industrial systems and products based on
biological principles found in nature.
o Sustainability Through Biomimicry: Draws inspiration from nature's efficiency and
adaptability to create sustainable solutions that minimize environmental impact and
enhance resource efficiency.
Life Cycle Assessment (LCA)
- Life Cycle Assessment (LCA) is a
methodology used to evaluate the
environmental impacts of a product,
process, or service throughout its entire
life cycle, from raw material extraction
to final disposal.

- LCA provides a comprehensive analysis

of the environmental burdens
associated with each stage of the life
cycle, including resource extraction,
manufacturing, distribution, use, and
end-of-life treatment.

Steps For LCA Methodology :

o Goal and Scope Definition:
 The first step in conducting an LCA is to define the goals and scope of the study, including the
functional unit being assessed and the system boundaries.
 Goals may include identifying environmental hotspots, comparing different product options,
or informing decision-making processes.
o Life Cycle Inventory (LCI):
 LCI involves compiling a detailed inventory of all inputs (e.g., raw materials, energy, water)
and outputs (e.g., emissions, waste) associated with each stage of the product's life cycle.
 Data collection may involve primary data from manufacturers, secondary data from
databases, or modeling techniques.
o Life Cycle Impact Assessment (LCIA):
 LCIA evaluates the potential environmental impacts of the life cycle inventory data using
impact categories such as climate change, resource depletion, water pollution, and human
health effects.
  LCIA characterizes the inventory data into impact indicators, quantifies the environmental
burdens, and assesses their significance.
o Interpretation:
 The interpretation phase involves analyzing and synthesizing the results of the LCA to draw
conclusions and make recommendations.
 This may include identifying environmental hotspots, evaluating trade-offs between different
impact categories, and exploring opportunities for improvement.
o Improvement Assessment:
 Based on the findings of the LCA, stakeholders can identify opportunities to reduce
environmental impacts and improve the sustainability performance of the product or
process.
 This may involve redesigning products, optimizing processes, sourcing materials more
sustainably, or implementing end-of-life strategies such as recycling or reuse.
o Reporting and Communication:
 The results of the LCA are typically documented in a report that communicates the
methodology, findings, and conclusions to stakeholders.
 Effective communication of LCA results is crucial for informing decision-making, promoting
transparency, and engaging stakeholders in sustainability initiatives.

- Life Cycle Assessment provides a holistic approach to assessing the environmental impacts of products
and processes, enabling informed decision-making and continuous improvement towards sustainability
goals.
- It is widely used across industries to support sustainable design, procurement, and resource
management practices.
Bio Mimicry : -
- Bio mimicry is an approach to innovation that seeks sustainable solutions to human challenges by
emulating nature’s time-tested patterns and strategies.
- Nature's Lessons: Biomimicry is about learning from nature's solutions to solve human problems.
- Creative Inspiration: It involves getting ideas from animals, plants, and microorganisms to design
innovative solutions.
- Efficient and Sustainable: Biomimetic designs aim to be both effective and eco-friendly, mimicking
nature's resourcefulness.
- Interdisciplinary Collaboration: It requires teamwork across different fields like biology, engineering,
and design.
- Real-world Applications: Biomimicry is used in various industries, from architecture to medicine, to
create smarter and greener technologies.
- Respect for Nature: It promotes a deeper appreciation for the environment and ethical considerations
in innovation.
- Making Our World Better: Ultimately, biomimicry helps us make our world more sustainable, inspired
by the genius of nature.
Sustainable Design :-
- Nature-Inspired Solutions: Sustainable design takes cues from nature to create eco-friendly solutions.
- Reduce, Reuse, Recycle: It focuses on minimizing waste and maximizing resource efficiency through
practices like recycling and upcycling.
- Energy Efficiency: Sustainable designs aim to conserve energy and reduce carbon footprint by utilizing
renewable energy sources and optimizing energy use.
- Longevity and Durability: Products are designed to last longer, reducing the need for frequent
replacements and minimizing environmental impact.
- Material Selection: Sustainable design prioritizes the use of environmentally friendly materials that are
non-toxic, renewable, and biodegradable.
- Life Cycle Thinking: It considers the entire life cycle of a product, from production to disposal, to
minimize environmental impact at every stage.
- Community and Social Impact: Sustainable design takes into account social equity and community well-
being, ensuring that designs benefit society as a whole.
- Holistic Approach: It involves interdisciplinary collaboration and holistic thinking to address complex
environmental and social challenges.
- Regenerative Design: Sustainable design seeks to restore and regenerate ecosystems, aiming for
positive environmental impacts beyond mere sustainability.
- Education and Awareness: It promotes education and awareness about environmental issues,
encouraging individuals and industries to adopt sustainable practices.
Schematic Overview Of Making A Sustainable Design :-
- Research and Analysis:
o Understand the problem or need.
o Research environmental impacts and existing solutions.
o Identify key stakeholders and their requirements.
- Goal Setting and Planning:
o Define goals and objectives for sustainability.
o Establish design criteria and constraints.
o Develop a plan for the design process, including timelines and resources.
- Concept Generation:
o Brainstorm ideas and concepts for sustainable solutions.
 o Explore nature-inspired designs and biomimicry principles.
o Consider alternative materials, energy sources, and technologies.
- Evaluation and Selection:
o Assess each concept against sustainability criteria.
o Use tools like Life Cycle Assessment (LCA) to evaluate environmental impacts.
o Select the most promising design based on sustainability performance.
- Design Development:
o Refine the chosen concept to optimize sustainability.
o Incorporate feedback from stakeholders and experts.
o Use sustainable materials, energy-efficient technologies, and innovative techniques.
- Prototyping and Testing:
o Build prototypes to test the design's functionality and performance.
o Conduct experiments to verify sustainability claims.
o Gather feedback from users and conduct usability testing.
- Refinement and Iteration:
o Analyze test results and identify areas for improvement.
o Iterate on the design to address any issues or concerns.
o Optimize sustainability features while maintaining functionality and performance.
- Implementation and Production:
o Finalize the design for production.
o Ensure that manufacturing processes are environmentally friendly.
o Consider factors like energy efficiency, waste reduction, and supply chain sustainability.
- Monitoring and Evaluation:
o Monitor the performance of the sustainable design in real-world settings.
o Collect data on energy consumption, material usage, and environmental impact.
o Evaluate the design's effectiveness in meeting sustainability goals.
- Feedback and Adaptation:
o Gather feedback from users, stakeholders, and environmental assessments.
o Use insights to make adjustments and adaptations to the design.
o Continuously improve the design based on new information and evolving sustainability
standards.
Recycling Overview:
- Recycling involves recovering materials or components from products for processing.
- Metals recycling is well-established, often done through shredding and separation or disassembly
and recycling methods.
- Plastics recycling is less established but can be achieved through mechanical methods, sorting,
melting, and granulation.
Plastics Recycling:
- Mechanical recycling: melting, shredding, and granulation.
- Plastics sorted by polymer type/color before melting or granulation.
- Specialist recycling for components like PCBs, batteries, CRT.
Specialist Recycling:
- PCBs from IT/telecom equipment have intrinsic value.
- Pyrolytic treatment (smelting) extracts precious metals (silver, lead, copper, gold).
Design for Recyclability:
- Design for recyclability is emphasized in sustainable development, aiming to preserve the
environment.
- Key guidelines include increasing energy efficiency, minimizing material usage, and using recyclable
or biodegradable materials.
Remanufacturing:
- Process of refurbishing/recycling products for reuse.
- Promotes sustainability by extending product life cycle.
Ecodesign and Design for Sustainability:
- Environmental philosophies have evolved from green design to eco-design and now to design for
sustainability.
- Eco-design aims to reduce the environmental impact of each stage of the product life cycle, from
extraction to disposal.
Product Life Cycle:
- The product life cycle encompasses all stages from raw material extraction to disposal.
- Eco-design focuses on improving environmental impact at each stage, including extraction,
manufacturing, distribution, use, and disposal.

Design for
Aspect Green Design Eco Design Sustainability
Sustainability
Minimizing Reducing Integrating Achieving balance
environmental environmental environmental, between
Focus
impact through impact throughout social, and economic environmental, social,
design. the product lifecycle. considerations. and economic factors.
Broadens focus to
Encompasses broader
include social and Considers
Primarily focuses on goals beyond design,
economic factors environmental,
Scope environmental including societal well-
alongside social, and economic
aspects. being and economic
environmental aspects of design.
viability.
concerns.
Reduce resource Minimize Optimize resource Ensure long-term
Objectives
consumption, energy environmental efficiency, social balance and harmony
 between human
use, and waste impact at each stage equity, and economic
activities and the
generation. of product life cycle. viability.
natural environment.
Incorporating
Promoting
sustainable Considering life cycle
Designing for conservation,
materials, energy- impacts, social
recyclability, responsible resource
Strategies efficient equity, and economic
reusability, and use, and equitable
technologies, and viability in design
renewable resources. distribution of
waste reduction decisions.
resources.
measures.
Engaging with
Collaboration with Engaging with Involving various
communities,
environmental diverse stakeholders stakeholders to
governments,
Stakeholder experts and to address integrate
businesses, and
Engagement stakeholders to environmental, sustainability
organizations to
implement green social, and economic principles into design
promote sustainability
solutions. concerns. processes.
initiatives.
Cradle-to-cradle
Energy-efficient Sustainable urban Conservation efforts,
design, renewable
buildings, recyclable planning, green renewable energy
energy systems, and
Examples packaging, and infrastructure, and adoption, and
eco-friendly
sustainable product socially responsible equitable access to
transportation
design. business practices. resources.
solutions.

- Good Design Principles:

o Rationalized number of materials and components.
o Consideration of consumer health, safety, and functionality.
o Clear communication of product function and appropriate styling.
o Ergonomic correctness and compliance with legislation.
- Eco-Design Focus:
o Aims to reduce environmental impact at every stage of the product life cycle.
o Goes beyond traditional design considerations to prioritize sustainability.
- Product Life Cycle:
o Encompasses all stages from raw material extraction to end-of-life disposal.
o Includes extraction, manufacturing, distribution, use, and disposal phases.
- Eco-Design Objectives:
o Focuses on improving environmental impact at each stage of the product life cycle.
o Seeks to minimize resource consumption, energy use, and waste generation throughout the
product's life span.
Expanded Scope of Design for Sustainability:
- Considers social issues such as usability, socially responsible use, and addressing human needs.
- Includes aspects like ergonomics, inclusive design, and design against crime, which are often viewed
separately.
Social Issues Considered:
- Usability, socially responsible use, and sourcing are among the social issues addressed.
- However, some issues like sustainable procurement and ethical labor sourcing may require strategic-
level intervention.
Approaches to Design for Sustainability:
- Can be approached by focusing on human needs, which can lead to a holistic consideration of
sustainability.

Social Innovation :-
Definition of Social Innovation:
- Social innovation is the development and implementation of effective solutions to complex social
and environmental issues, aimed at promoting social progress.
Examples of Social Innovations:
- Charter Schools: Publicly funded schools with flexibility in regulations, allowing for innovative
teaching methods.
- Emissions Trading: Pollution control program using economic incentives to reduce emissions by
setting caps and issuing permits.
- Fair Trade: Movement establishing trade standards to ensure fair wages and environmental
sustainability in product supply chains.
Drivers of Social Innovation:
 o Exchange of ideas and values, shifts in roles and relationships, and integration of private capital
with public and philanthropic support are key mechanisms driving social innovation.
Importance of Collaboration:
o Involvement of nonprofit, public, and private sectors is crucial for addressing complex social
problems effectively.
 Module 04 : Metaphors & Prototyping
Metaphor Method In Concept Generation
o It’s a rhetorical figure representing one concept by the way of another concept.

First Order Concept Generation :-

o It is used to create a subspecies of an existing object
o It cant extend beyond the category of an existing product.
o Abstract concept generated by combining multiple abstract concepts is called a high-order
abstract concept
o The high-order concept generation is the process of generating a new concept on the basis of
this high-order abstract concept.
Making Up New Ideas: Easy Guide to Higher-Order Concept Generation
Imagine you're coming up with new ideas. Here's how higher-order concept generation helps:
 Level 1: Refining Existing Ideas (First-Order): This is like making a new type of an existing thing.
Think "red car" instead of just "car." It's still a car, but with a twist.
 Level 2: Creating Truly New Ideas (High-Order): This is about going beyond tweaks and inventing
something entirely new. It involves combining existing ideas in surprising ways.
Let's see the difference:
 White Tomato: This is a first-order concept. It's a tomato, but a different color. It doesn't break the
mold of what a tomato is.
 Powdered Ketchup: This is a high-order concept. It combines the idea of a dry powder (like snow)
with the flavor of a condiment (like ketchup). It's something entirely new!
How We Combine Ideas:
There are two main ways to do high-order concept generation:
 Blending: Imagine you take parts of two ideas and smash them together. Powdered ketchup is a
blend of "powder" and "ketchup."
 Thematic Integration: This is like finding a new connection between two ideas. Imagine finding a
common theme between "traveling by car" and "traveling by plane." Maybe the theme is "fast
transportation" and this could inspire a new type of high-speed travel pod!
Key Points:
 High-order concept generation is about creating truly new ideas by combining existing ones in
surprising ways.
 Blending takes parts of two ideas and merges them.
 Thematic integration finds a common theme between two ideas, sparking a new concept.

Left Brain vs. Right Brain Thinking

Feature Left Brain Right Brain

Thinking Critical Creative

Function Analytical, logical, sequential Creative, holistic, intuitive

Language, math, logic, reasoning, Spatial reasoning, imagery, rhythm,

Skills
analysis emotions, intuition

Reading, writing, problem-solving, Music, art, design, daydreaming,

Activities
critical thinking emotions

Accuracy, order, detail-oriented, Originality, seeing the big picture,

Strengths
rule-based connecting ideas

Completing a math equation, Painting, composing music, brainstorming

Examples
analyzing data, following instructions ideas, understanding emotions

Solutions Leads To Only One Solution Creates Many Possible Solution

Information Consider Only Relevant Information Consider Very Broad Information

Convergent Divergent

Creativity and Problem Solving

What Makes Someone Creative?
 Mixing and Matching Ideas: Creative thinkers are like chefs in the kitchen. They can take different
ingredients (ideas and concepts) and combine them in new and interesting ways to create
something delicious (meaningful and useful).
 Seeing Things Differently: Creative people can break down existing ideas and look at them from a
fresh perspective. They can also connect seemingly unrelated things to come up with new solutions.
  Building on What We Know: While we all love a good original idea, most creativity comes from
putting existing ideas together in new ways. Think of it like remixing a song – familiar elements used
in a fresh way!
The Myth of Instant Genius:
 Creativity Isn't Magic: There's a misconception that creative ideas just appear out of nowhere.
While some inspiration can strike suddenly, most creative ideas require effort and hard work.
Tools for Boosting Creativity:
 Embrace the "Creative Mindset": Believe in your ability to come up with new ideas.
 Let Your Imagination Run Wild: Don't be afraid to explore strange and unusual ideas – sometimes
the craziest ideas lead to the best solutions!
 Keep Trying: Don't give up easily! The best ideas often come after several attempts and revisions.
 Be Open to New Things: Be curious and explore different ways of thinking and seeing the world.
 Don't Be Afraid to Be Wrong: Don't let the fear of failure hold you back. Sometimes the best way to
learn is through trial and error.
 Focus on the Problem: Define the problem you're trying to solve clearly. This will help you stay on
track and avoid getting sidetracked.
Aids to Creative Thinking :
 Develop Creative Mind
 Unlock Your Imagination
 Be Persistent
 Develop an Open Mind
 Suspend Your Judgement
 Set Problem Boundaries
Barriers to Creativity :-
o Lack of Tools
o Negative Attitude
o Lack Of Self Motivation
o Lack Of Self Confidence
o Too Many Rules & Formalization
o Country Culture
o Economic & Political Situation
o Corporate Culture
o Family Background
o Education System
o Stress Level
o Lack Of Excercising

Communication
o It’s the process of sending and receiving messages through verbal and nonverbal means.

Articulate Design Ideas

 o Process of clearly and effectively communicating concepts, visions and solutions within the
context of design.
o Key Aspects
o Clarity & Precision
o Engagement
o Relevance
o Feedback Incorporation

Designing Purpose :-
 Solve A Problem : What problem does this particular design solve? Always refer to the problem,
goals and big picture.
 Be Easy For Users : How does this particular design affect the user? What barriers are we creating
or minimizing?
 Be Supported By Everyone : There will always be someone who will challenge your decision. Be
prepared to explain why it's better than the alternative and the other directions you explored.
Documentation Benefits :-
 Avoid Repeat Conversation
o Clarity & Reference
o Efficiency
o Consistency
 Focuses On Being Articulate
o Clear Communication
o Precision
o Comprehensive
 Build Trust With Stake Holders
o Transparency
o Accountability
o Engagement
 Keeps the Meeting On Track
o Agenda & Focus
o Reference Material
o Decision Making

Story Telling :-
o Its Powerful Communication Tool
o The interactive art of using words and actions to reveal the elements and images of a story
while encouraging the listener's imagination.
o A technique to get insight into users, build empathy and access them emotionally

Benefits Of Story Telling :-

 Content
 History
 Creative
 Experience
 Marketing
 Communication
 Emotion
  Share
Evolution Of Story Telling :-

Printing

Word Of
Mouth

Mobile

VR / 360 /
AR

Seven Elements In Story Telling :-

o User's Journey: What problem are they facing? How does your design help them win?
o Know Your Users: Who are you designing for? What are their needs and frustrations?
o Build Trust: Show users your design is a reliable friend.
o Design's Language: What message does your design "speak" to users? Is it clear and inviting?
o Feel the Feels: Does your design create a positive experience? Does it make them happy to use
it?
o Setting the Scene: Create a clear and engaging visual experience for users.
o Make it Memorable: What sets your design apart?

Six Rules in Storytelling

1. Self knowledge and awareness
2. Clear structure and purpose
3. Have a character to root
4. Appeal to our deepest emotions
5. Surprising and unexpected
6. Simple and focused
Sketching :-
o Sketch is a rapidly executed freehand drawing that is not considered as finished work.

Purpose Of Sketching :-
o Recording Observation
o Developing Ideas
o Demonstrating Concept (Visual / Graphical Representation)
Mediums Used In Sketching :-
o Dry Medium
o Silverpoint, Pencil, Charcoal, Pastel
o Pen & Ink
o Ink Pens, Marker Pens, Color Pens
o Digital Input
o Digital Pen, Software Tools
o Wet Medium
o Water Color, Oil Paint
o Three Dimensional Sketching
o Clay, Plasticine Or Wax

K Script :-
o The fastest and most flexible way to articulate a user experience

K-Scripts for Engineering Design: A Simple Explanation

o K-Scripts are a communication tool specifically designed for User Experience (UX) designers, but
they can also be helpful in engineering design modeling. Here's a breakdown of what they are
and how they can be used:
What are K-Scripts?
o Imagine a quick and easy way to outline how someone interacts with a product or system. That's
essentially what a K-Script is. It uses a simple table format to describe user actions and the
system's responses.
Why use K-Scripts in Engineering Design Modeling?
 Early Communication: K-Scripts can help you communicate design ideas early on, allowing for quick
feedback and iteration.
 Focus on User Interaction: By outlining user actions and system responses, K-Scripts can help ensure
your design is user-friendly.
 Documenting Design Decisions: K-Scripts serve as a record of your design thinking and decision-
making process.
Values Of K-Script :-
o Focus On 80% Case That User Will Encounter
o Addressing Failure Condition
o Versatility In Context

What information goes in a K-Script?

Each K-Script typically has three columns:
1. Who: This identifies the actor performing the action (user, system, etc.)
2. What: This describes the observable action taken.
3. Unobservable Action: This explains the reasoning behind the action or any technical details that
might not be immediately obvious.
K-Scripts Explained with Everyday Examples

Imagine K-Scripts as conversation starters for your engineering design. They use three simple columns to
explain how someone interacts with a product (or system) you're designing.

The Columns:
1. Who: This is like saying "The Actor" in a play. Who is taking the action? It could be the user, the
system itself, or even another part of your design.
2. What: This is the action that happens. What can the user do, or what does the system do in
response?
3. Unobservable Action: This is like explaining the "why" behind the scenes. It might be the user's
thought process, a technical detail, or anything that helps understand the interaction better.
Here's how it works with some simple examples:
Example 1: Coffee Machine
Who What Unobservable Action
User Pushes the "Brew" button User wants a cup of coffee.
Coffee Starts grinding coffee beans Machine prepares for brewing.
Machine
Unobservable Grinder activates and crushes coffee Grinding mechanism uses blades to break down
beans beans.
Example 2: Automatic Door
Who What Unobservable Action
Person Walks towards the door Person wants to enter.
Automatic Sensor detects approaching person and Sensor uses infrared to identify movement.
Door opens
Unobservable Door opens smoothly using a silent motor Motor powers a belt system to slide the door
open.

Benefits of K-Scripts:
 Simple and Flexible: Easy to create and adapt to different scenarios.
 Improves Communication: Provides a clear picture of how users will interact with the design.
 Promotes Collaboration: Helps designers and engineers work together more effectively.
 Simple & Fast: They're easy to create and understand, saving you time and effort.
 Crystal Clear Communication: K-Scripts help everyone (designers, engineers, anyone!) see exactly
how users will interact with your design. No more confusion!
 User in the Spotlight: K-Scripts keep the focus on how users will actually use your design, making
sure it's user-friendly and solves their problems.
 Early Feedback FTW! Get feedback on your ideas early on with K-Scripts, allowing you to make
improvements before things get too complicated.
 Documenting Your Journey: K-Scripts act like a record of your design thinking, showing the steps
you took and the reasons behind your decisions.
  Collaboration Made Easy: K-Scripts help designers and engineers work together more smoothly by
providing a shared understanding of the design.
When K-Script are Used :
o New Idea Pow!: Need to explain a brand new design concept? K-Scripts are perfect! They paint a
clear picture for anyone, even if they haven't seen your product before.
o Early Bird Gets the Feedback: Use K-Scripts early on in the design process. This lets you get
feedback quickly and make improvements before things get complicated.
o Constantly Evolving: Your design will change as you work on it. K-Scripts are flexible! Update
them as your ideas evolve to keep everyone informed.
o Show & Tell Time: Combine K-Scripts with a simple prototype. This lets people experience the
interaction and understand how complex the final design might be.
o Universal Language: K-Scripts use plain language, so even people outside design (clients,
investors) can understand them with some context.
o Focus on the Usual: Use K-Scripts for the most common interactions users will have with your
design. For rare or complex situations, use more detailed diagrams.
o Keep it Simple: Don't overload your K-Script with too much info. They're meant for quick
communication, not a whole story!
o The Big Picture: Use a set of K-Scripts together to show how different parts of your design work
as a whole system. This helps everyone see the complete vision.
Rapid Prototyping :-
o Fundamental Automated Process
o Subtractive
 In this process, a single block of material is taken which is
larger than final size of the desired object.
 Portions of the material are removed until the desired
shape is reached.
 Ex: CNC, Milling,etc .
o Additive
 It is exact opposite of the subtractive process.
 In this the end product is larger than the initial material.
 Ex: SLS, LOM etc.
o Formative
 Mechanical forces are applied on a material so as to form it
into desired shape.
 Ex: Bending, Forging etc.
 o Process Chain
Eight Key Steps In The Additive Process
Chain
The list you provided describes the eight
steps involved in creating an object using
Additive Manufacturing (3D printing).
o Conceptualization and CAD: This is

where you dream up your idea! You

can sketch it out on paper, write a

description, or use a computer

aided design (CAD) program to create a digital 3D model of your object.

o Conversion to STL: Imagine your 3D model is made of millions of tiny triangles. Converting

the model to STL format creates a set of instructions for the 3D printer based on these

triangles.

o Transfer and manipulation: You send the STL file to the 3D printer and might make some

adjustments. You can change the position of the object or add markings like your name.

o Machine setup: Just like any machine, the 3D printer needs to be prepared for the job. This

involves choosing the right material and setting the printing parameters.

o Build: This is the exciting part! The 3D printer starts building your object one layer at a time,

following the instructions in the STL file.

o Part removal and clean-up: Once the printing is complete, you need to carefully remove the

object from the 3D printer and clean up any leftover material.

o Post-processing: The fresh-out-of-the-printer object might need some extra work. This could

involve sanding it smooth, adding paint, or any other finishing touches you desire.

o Application: Finally, your creation is ready for use! You can put it on display, use it for a

project, or anything else you envisioned.

Chapter 3 dives into Liquid-Based Rapid Prototyping Systems, with Stereolithography Apparatus (SLA) as

the first example. Here's a summary of SLA technology:

Invented by Charles Hull in the 1980s, SLA uses a laser to solidify liquid resin into complex 3D objects.

Process:

1. Preparation: A vat holds liquid resin, and a 3D model is sliced into thin layers for computer control.

2. Layer-by-Layer Building: A laser beam scans a single layer of the model onto the resin, solidifying it

based on the sliced data.

3. Repetition: The platform holding the solidified layer lowers slightly. Fresh resin recoats the top, and

the laser creates the next layer on top. This repeats until the entire 3D object is built.

4. Finishing Touches: After printing, the object is removed, cleaned of excess resin, and might require

additional curing with light.

Advantages of SLA:

 Continuous operation: Runs without constant monitoring.

 Accuracy and finish: Produces high-precision objects with smooth surfaces.

 Material variety: Offers a wide range of resin materials for different properties.

Disadvantages of SLA:

 Support structures: Requires temporary supports to hold the object during printing.

 Post-processing: Needs cleaning and potentially extra curing after printing.

Photopolymerization is the underlying principle of SLA.

Photopolymers are light-sensitive liquids that harden when exposed to light. In SLA, a laser beam acts as

the light source, solidifying the resin layer by layer. This process relies on photoinitiators, which are

activated by light to trigger a chain reaction that hardens the liquid resin.
 Module 05 : Materials & Modelling

Ferrous Metals

Engineering Materials
Metals
Non Ferrorus
Metals

Ceramics

Organics

Non-Metals Composites

SemiConductors

Other

Metals :
- Elements which are composed of one or more metallic elements (such as iron, aluminium,
copper, titanium, gold & nickel)
- Good Conductors Of Heat & Electricity
- Good Electrical Conductors , as number of valence electrons are high which helps in creation of
the metallic bond.
- Types Of Metal :-
o Ferrous Metals :
 Iron As Main Constituent
 Ex. : Cast-Iron, Wrought Iron & Steel
o Non – Ferrous Metals :
 Elements Which Don’t Contains Iron
 Copper, Aluminium, Zinc, Brass, Tin
Alloys :
- Mixture of two or more than two metals or non-metals to obtained the desired properties of
metals.
- Ex. : Stainless Steel(SS), High Speed Steel (HSS)
Non-Metals :
- Elements which don’t exist naturally but made artificially.
- Used In Engineering practices due to their low density, low cost, flexibility, resistant to heat and
electricity
Ceramics :
- Compounds between Metallic & Non-Metallic Elements.
 - Hard & Brittle
- Bad Conductor of Heat & Electricity
- Ex. : China Tea Cup, Building Bricks, Floor Tiles, Glass etc.
Composites :
- A composite is composed of two (or more) individual materials (metals, ceramics, and
polymers).
- A composite is made to achieve a combination of properties that is not displayed by any single
material.
- Ex:- Carbon Fiber Reinforced Polymer, Carbon Fiber.
Semi-Conductors :
- Those materials whose conductivity is lies between conductor and insulator are called
semiconductors.
Mechanical Properties :
The mechanical properties of the metals are those which are associated with the ability of the material to

resist mechanical forces and load.

- Strength: It is the ability of a material to resist the externally applied forces without breaking or

failure.

- Stiffness: It is the ability of a material to resist deformation under stress.

- Elasticity: It is the property of a material to regain its original shape after deformation when the

external forces are removed. This property is desirable for materials used in tools and machines.

- Plasticity: It is property of a material which does not regain its original shape after deformation

when the external forces are removed. This property of the material is necessary for forgings, in

stamping images on coins and in ornamental work.

- Ductility: It is the property of a material enabling it to be drawn into wire with the application of

a tensile force. Ex: Mild Steel, Copper, Aluminum, Nickel, Zinc, Tin and Lead.

- Brittleness: It is the property of a material opposite to ductility. It is the property of breaking of

a material with little permanent distortion. Ex: Cast Iron, Glass etc.

- Malleability: It is a special case of ductility which permits materials to be rolled or hammered

into thin sheets. Ex-lead soft steel wrought iron copper and aluminum etc.

Some Engineering Materials :

- Cast Iron
 o Obtained by remelting pig iron with coke and limestone in a furnace known as cupola.

o Primarily Alloy Of Iron & Carbon

o Carbon Content 1.7% to 4.5%

- Grey Cast Iron

o Ordinary Commercial Iron

o Grey Color

o Carbon Present in Form Of Free Graphite

o Low Tensile Strength, High Compressive Strength & No Ductility

o Easily Machined

- White Cast Iron

o It Shows White Fracture

o The white colour is due to fact that it has no graphite and whole of the carbon is in the

form of carbide (known as cementite) which is the hardest constituent of iron.

o The white cast iron has a high tensile strength and a low compressive strength.

- Malleable Cast Iron

o It is ductile and may be bent without breaking or fracturing the section.

o The tensile strength of the malleable cast iron is usually higher than that of grey cast

iron and has excellent machining qualities.

- Wrought Iron

o It is the purest iron which contains at least 99.5% iron but may contain upto 99.9% iron.

o The typical composition of a wrought iron is Carbon = 0.020%, Silicon = 0.120%, Sulphur

= 0.018%, Phosphorus = 0.020%, Slag = 0.070%, and the remaining is iron.

- Steels

o It is an alloy of iron and carbon, with carbon content up to a maximum of 1.5%.

o Dead mild steel - up to 0.15% carbon

o Low carbon or mild steel - 0.15% to 0.45% carbon

 o Medium carbon steel-0.45% to 0.8% carbon

o High carbon steel - 0.8% to 1.5% carbon

- 18-4-1 High Speed Steel

o This steel, on an average, contains 18% tungsten, 4% chromium and 1% vanadium

o It is considered to be one of the best of all purpose tool steels. It is widely used for drills,

lathe, planer and shaper tools, milling cutters, reamers, broaches, threading dies,

punches, etc.

Loads On Materials :

- Normal Load (Axial load): Load is perpendicular to the supporting material.

- Tension Load: As the ends of material are pulled apart to make the material longer, the load is

called a tension load.

- Compression Load: As the ends of material are pushed into make the material smaller, the load is

called a compression load.

 - Torsion Loads: Angular distortion on a component, such as a shaft, when a moment is applied.

(Twisting)

- Thermal Loads: Distortion caused be heating or cooling a material. A normal load is created when

the material is constrained in any direction in the plane that is constrained.

Stress & Strain :

Stress : Load Per Unit Area

Strain : Ratio of elongation of a material to the original length & Unit Deformation

Stress – Strain Diagram :-

- It gives us the behaviour of the material and materials properties.

Elastic Region (Point 1 –2)

- The material will return to its original shape after the material is unloaded( like a rubber band).

- The stress is linearly proportional to the strain in this region.

- Point 2 : Yield Strength : a point at which permanent deformation occurs. (If it is passed, the

material will no longer return to its original length.)

Elastic Range :

- The strain, or elongation over a unit length, will behave linearly (as in y=mx +b) and thus

predictable.

- The material will return to its original shape (Point 1) once an applied load is removed.

- The stress within the material is less than what is required to create a plastic behaviour (deform or

stretch significantly without increasing stress).

Plastic Region (Point 2 –3)

- If the material is loaded beyond the yield strength, the material will not return to its original shape

after unloading.

- It will have some permanent deformation.

 - If the material is unloaded at Point 3, the curve will proceed from Point 3 to Point 4. The slope will

be the as the slope between Point 1 and 2.

- The distance between Point 1 and 4 indicates the amount of permanent deformation.

Strain Hardening

- If the material is loaded again from Point 4, the curve will follow back to Point 3 with the same

Elastic Modulus(slope).

- The material now has a higher yield strength of Point 4.

- Raising the yield strength by permanently straining the material is called Strain Hardening.

Tensile Strength (Point 3)

- The largest value of stress on the diagram is called Tensile Strength(TS) or Ultimate Tensile Strength

(UTS)

- It is the maximum stress which the material can support without breaking.

Fracture (Point 5)

- If the material is stretched beyond Point 3, the stress decreases as necking and non-uniform

deformation occur.

- Fracture will finally occur at Point 5.

Characteristics Of Materials are Described As :

- Strength

o Measure of the material property to resist deformation and to maintain its shape

o It is quantified in terms of yield stress or ultimate tensile strength .

o High carbon steels and metal alloys have higher strength than pure metals.

o Ceramic also exhibit high strength characteristics

- Hardness

o Measure of the material property to resist indentation, abrasion and wear.

 o It is quantified by hardness scale such as Rockwell and Brinell hardness scale that measure

indentation / penetration under a load.

o Hardness and Strength correlate well because both properties are related to inter-molecular

bonding. A high-strength material is typically resistant to wear and abrasion.

- Ductility

o Measure of the material property to deform before failure.

o It is quantified by reading the value of strain at the fracture point on the stress strain curve.

o Ductile materials can be pulled or drawn into pipes, wire, and other structural shapes

o Examples of ductile material: low carbon steel aluminium, copper, brass

- Brittleness

o Measure of the material’s inability to deform before failure.

o The opposite of ductility.

o Example of ductile material : glass, high carbon steel, ceramics

- Toughness

o Measure of the material ability to absorb energy.

o It is measured by two methods.

 Integration of stress strain curve

 Slow absorption of energy

 Absorbed energy per unit volume unit : (lb/in²) *(in/in) =lb·in/in³

 Charpy test

 Ability to absorb energy of an impact without fracturing.

 Impact toughness can be measured

Fatigue :

- The repeated application of stress typically produced by an oscillating load such as vibration.

- Sources of ship vibration are engine, propeller and waves

*MAXIMUM Stress Decreases as the Number Of Loading Cycle Increases*

 Factors Affecting Material Properties :-

- Temperature

o Increasing Temperature Will

 Decrease Modulus of Elasticity (As Long as Structure Does Not Change)

 Decrease Yield Strength

 Decrease Ultimate Tensile Strength

 Decrease Hardness

 Increase Ductility

 Decrease Brittleness

- Environment

o Sulfites, Chlorine, Oxygen in water, Radiation, Pressure

Ways To Effect / Alter Material Properties :

- Alloying (Adding other elements to alter the molecular properties): -

o Steel: Carbon, chromium, molybdenum, nickel, tungsten, manganese

o Aluminum: Copper, manganese, silicon, zinc, magnesium

Thermal Treatments(Application of heat over varying time):

- Annealing:
 o Heating higher than its critical temperature then cooling slowly.

o Improves hardness, strength, and ductility.

o Ship’s hulls are annealed.

- Hardening:

o Heating higher than its critical temperature then cooling rapidly.

o Improves hardness.

o Increases internal stresses, may cause cracking

- Tempering:

o Steel is heated below the critical temperature and cooled slowly.

o Used with hardening to reduce the internal stresses

- Hot-Working:

o Forming of shapes while material is hot.

o Less internal stresses due to annealing (change in the molecular structure).

- Cold-Working:

o Forming shapes while material is cold.

o Causes internal stresses, resulting in a stronger shape