FOREWORD x PREFACE xi ACKNOWLEDGMENTS xvi PART I INTRODUCTION 1 CHAPTER 1 ENGINEERING DESIGN What does it mean to design something? Is engineering design different from other kinds of design? 3 1.1 Where and when do engineers design? 3 1.2 A basic vocabulary for engineering design 7 1.3 Learning and doing engineering design 12 1.4 Managing engineering design projects 14 1.5 Notes 15 CHAPTER 2 DEFINING A DESIGN PROCESS AND A CASE STUDY How do I do engineering design? Can you show me an example? 16 2.1 The design process as a process of questioning 16 2.2 Describing and prescribing a design process 19 2.3 Informing a design process 24 2.4 Case study: Design of a stabilizer for microlaryngeal surgery 27 2.5 Illustrative design examples 34 2.6 Notes 35 PART II THE DESIGN PROCESS AND DESIGN TOOLS 37 CHAPTER 3 PROBLEM DEFINITION: DETAILING CUSTOMER REQUIREMENTS What does the client require of this design? 39 3.1 Clarifying the initial problem statement 40 3.2 Framing customer requirements 41 3.3 Revised problem statements: Public statements of the design project 43 3.4 Designing an arm support for a CP-afflicted student 44 3.5 Notes 46 CHAPTER 4 PROBLEM DEFINITION: CLARIFYING THE OBJECTIVES What is this design intended to achieve? 47 4.1 Clarifying a client s objectives 47 4.2 Measurement issues in ordering and evaluating objectives 53 4.3 Rank ordering objectives with pairwise comparison charts 54 4.4 Developing metrics to measure the achievement of objectives 57 4.5 Objectives and metrics for the Danbury arm support 62 4.6 Notes 66 CHAPTER 5 PROBLEM DEFINITION: IDENTIFYING CONSTRAINTS What are the limits for this design problem? 67 5.1 Identifying and setting the client s limits 67 5.2 Displaying and using constraints 68 5.3 Constraints for the Danbury arm support 69 5.4 Notes 70 CHAPTER 6 PROBLEM DEFINITION: ESTABLISHING FUNCTIONS How do I express a design s functions in engineering terms? 71 6.1 Establishing functions 71 6.2 Functional analysis: Tools for establishing functions 73 6.3 Design specifications: Specifying functions, features, and behavior 81 6.4 Functions for the Danbury arm support 88 6.5 Notes 91 CHAPTER 7 CONCEPTUAL DESIGN: GENERATING DESIGN ALTERNATIVES How do I generate or create feasible designs? 92 7.1 Generating the design space, a space of engineering designs 92 7.2 Navigating, expanding, and contracting design spaces 99 7.3 Generating designs for the Danbury arm support 101 7.4 Notes 105 CHAPTER 8 CONCEPTUAL DESIGN: EVALUATING DESIGN ALTERNATIVES AND CHOOSING A DESIGN Which design should I choose? Which design is best ? 106 8.1 Applying metrics to objectives: Selecting the preferred design 106 8.2 Evaluating designs for the Danbury arm support 111 8.3 Notes 113 PART III DESIGN COMMUNICATION 115 CHAPTER 9 COMMUNICATING DESIGNS GRAPHICALLY Here s my design; can you make it? 117 9.1 Engineering sketches and drawings speak to many audiences 117 9.2 Sketching 119 9.3 Fabrication specifications: The several forms of engineering drawings 122 9.4 Fabrication specifications: The devil is in the details 127 9.5 Final notes on drawings 129 9.6 Notes 130 CHAPTER 10 PROTOTYPING AND PROOFING THE DESIGN Here s my design; how well does it work? 131 10.1 Prototypes, models, and proofs of concept 132 10.2 Building models and prototypes 135 10.3 Notes 141 CHAPTER 11 COMMUNICATING DESIGNS ORALLY AND IN WRITING How do we let our client know about our solutions? 142 11.1 General guidelines for technical communication 143 11.2 Oral presentations: Telling a crowd what s been done 145 11.3 The project report: Writing for the client, not for history 150 11.4 Final report elements for the Danbury arm support 155 11.5 Notes 158 PART IV DESIGN MODELING, ENGINEERING ECONOMICS, AND DESIGN USE 159 CHAPTER 12 MATHEMATICAL MODELING IN DESIGN Math and physics are very much part of the design process! 161 12.1 Some mathematical habits of thought for design modeling 162 12.2 Some mathematical tools for design modeling 163 12.3 Modeling a battery-powered payload cart 177 12.4 Design modeling of a ladder rung 186 12.5 Preliminary design of a ladder rung 193 12.6 Closing remarks on mathematics, physics, and design 196 12.7 Notes 196 CHAPTER 13 ENGINEERING ECONOMICS IN DESIGN How much is this going to cost? 197 13.1 Cost estimation: How much does this particular design cost? 197 13.2 The time value of money 201 13.3 Closing considerations on engineering and economics 204 13.4 Notes 204 CHAPTER 14 DESIGN FOR PRODUCTION, USE, AND SUSTAINABILITY What other factors influence the design process? 205 14.1 Design for production: Can this design be made? 206 14.2 Design for use: How long will this design work? 209 14.3 Design for sustainability: What about the environment? 215 14.4 Notes 218 PART V DESIGN TEAMS, TEAM MANAGEMENT, AND ETHICS IN DESIGN 221 CHAPTER 15 DESIGN TEAM DYNAMICS We can do this together, as a team! 223 15.1 Forming design teams 223 15.2 Constructive conflict: Enjoying a good fight 227 15.3 Leading design teams 229 15.4 Notes 231 CHAPTER 16 MANAGING A DESIGN PROJECT What do you want? When do you want it? How much are we going to spend? 232 16.1 Getting started: Establishing the managerial needs of a project 232 16.2 Tools for managing a project s scope 234 16.3 The team calendar: A tool for managing a project s schedule 241 16.4 The budget: A tool for managing a project s spending 243 16.5 Monitoring and controlling projects: Measuring a project s progress 245 16.6 Managing the end of a project 248 16.7 Notes 249 CHAPTER 17 ETHICS IN DESIGN Design is not just a technical matter 250 17.1 Ethics: Understanding obligations 250 17.2 Codes of ethics: What are our professional obligations? 252 17.3 Obligations may start with the client ... 255 17.4 ... But what about the public and the profession? 256 17.5 On engineering practice and the welfare of the public 261 17.6 Ethics: Always a part of engineering practice 263 17.7 Notes 263 APPENDICES 264 APPENDIX A PRACTICAL ASPECTS OF PROTOTYPING 264 APPENDIX B PRACTICAL ASPECTS OF ENGINEERING DRAWING 279 APPENDIX C EXERCISES 300 REFERENCES AND BIBLIOGRAPHY 309 INDEX 315
