Module 4A – Design

Design Phase

Begin detailed design work for selected Final Design

This includes: 

  • math modeling
  • risk assessment & mitigation (DFMEA -design failure mode & effects analysis)
  • bill of materials (BOM),
  • purchase order,
  • part cost determination
  • profit/loss (P/L) statement
  • mfg process instructions (MPIs)
  • both a sub-assembly
  • final product design (Solidworks) approval process resulting in a final engineering design package submittal
  • final prototype design is manufactured/built/assembled
  • may also result in ECNs (engineering change notices) as a result of the manufacturing/build/assembly process prior to testing

Definition of a prototype

  • An original module on which something is patterned; archetype.
  • An individual that exhibits the essential features of a later type.
  • A standard or typical example.
  • A first full-scale and usually functional form of a new type or design of a construction.

Your team’s prototyping goal

Build/manufacture/assemble a team-designed “functional” device, and test essential performance measures of the product design.

Comparisons of prototypes (photos of wooden mockups) and final designs (3d models of the product to create)

Why build a prototype?

  1. Conceptualization: Demonstrate feasibility/practicality.
  2.  Verification and Testing: Verify performance modeling. Prove/disprove assumptions made.
  3.  Development – Refine the Design: Identify design deficiencies/improvement. Suggest a mass manufacturing process.
Table. Prototype Constraints
Time Cost Materials Tools/Process Personnel Tote Sizes
  • Planning: 1.5 weeks
  • Fabrication: 2.5 weeks
  • Testing: 1 week
  • $85 if purchased
  • $50 if donated
  • Stock from shop
  • Approved vendors
    (See Boyd Lab)
  • Grainger, McMaster, typically
  • Boyd Lab only (Requires training)
  • Team members
  • Width x Depth x Height (Measure for yourself)


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Introduction to Mechanical Engineering Design Copyright © 2023 by Jacqulyn A. Baughman is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License, except where otherwise noted.