The document provides an overview of the mechanical design process from marketing analysis through to reverse engineering. It outlines the key stages as: 1) Marketing analysis and brainstorming to define customer needs and generate design ideas. 2) Preliminary design to define the overall system configuration. 3) Detailed design involving material selection, calculations, prototyping and simulations. 4) Iterative design evaluation, testing and optimization. 5) Considerations for manufacturing, assembly, environment and reverse engineering to recreate existing designs.

1. Introduction into Mechanical Design -
Reverse Engineering

2. Agenda
• Introduction
• Design Process
• Marketing analysis
• Brainstorming
• Preliminary design
• Design review
• Detailed Design
• Design Evaluation
• Iterations
• Manufacturing
• Design for Manufacturing / Assembly
• Design for Environment
• Reverse Engineering
• Manufacturing trends in the research sector
• IET Inspec Direct Database
• IET Inspec Analytics
• IET digital library

3. Design Process
Marketing
analysis Brainstorming
Preliminary
Design
Design
Review
Detailed
Design
Design
Evaluation
Iterations /
Optimization
Manufacturing

4. Marketing analysis
• Customer needs
• Budget
• Design restrictions
• Specifications
• Problem definition
Brainstorming
1.Set a time limit.
2.Begin with a target problem/brief.
3.Refrain from judgment/criticism.
4.Encourage strange ideas.
5.Aim for quantity.
6.Build on others’ ideas.
7.Allow one conversation at a time.
8.Use a Decision matrix

5. Preliminary Design
Preliminary design
The preliminary design, or high-level design includes, often bridges a gap between
design conception and detailed design, particularly in cases where the level of
conceptualization achieved during ideation is not sufficient for full evaluation. So
in this task, the overall system configuration is defined, and schematics, diagrams,
and layouts of the project may provide early project configuration.
An essential phase in new product design and development is defining the
product’s exact characteristics. Impressions and conclusions from the research
stage are integrated with performance expectations, to create the initial design,
which defines the functional requirements and elements.

6. Design Review
A design review is a milestone within a product development process whereby a design is evaluated against its
requirements in order to verify the outcomes of previous activities and identify issues before committing to and if
need to be reprioritize further work. In addition a design review checklist should be used in the review process.

7. Detailed Design
Material selection
Material selection is the act of choosing the material best suited to achieve the requirements of a given
application. Many different factors go into determining the selection requirements, such as mechanical
properties, chemical properties, physical properties, electrical properties and cost.
Material Selection Charts

8. Detailed Design
Material selection
Material Selection Charts

9. Detailed Design
Design Calculations
When you have decided on the basic design for your device,
you will need to do the calculations to make sure that the
design will achieve the aim: how much force is required,
what size parts are needed, and so on.
Make sure that you double-check your own calculations (or
get a college to do it for you) and include all calculations in
your project documentation.
Simulations
Design simulation helps manufacturers verify and validate
the intended function of a product under development, as
well as the manufacturability of the product.
• Structural
• Thermal
• Vibrations
• Electrical
• Magnetism

10. Detailed Design
Prototype
A prototype is an early sample, model or release of
a product created to test a concept or process.
Typically, a prototype is used to evaluate a new
design to improve the accuracy of analysts and
system users. The visual representation of the
prototype demonstrates what the product is doing
at any given point, what the interactive elements
are, and how the product would function in the real
world.
3D printing
3D printing, or additive manufacturing, is the
construction of a three-dimensional object from a
CAD model or a digital 3D model. The term "3D
printing" can refer to a variety of processes in which
material is deposited, joined or solidified under
computer control to create a three-dimensional
object, with material being added together, typically
layer by layer.

11. Design Evaluation
Engineers evaluate designs for effectiveness to see if
they solve the problems that they were supposed to
solve, for consistency to make sure that the design
works the same way every time, and for efficiency to
make sure that it solves the problem in the simplest
way possible without any extra steps or pieces.
Testing
• Check for dimensional accuracy
• Collect test data
• Analyze test data
• Performance
• Usability
• Durability
• Validation of design
Examples
• Static structural
• Dynamic Structural
• Fatigue testing
• Thermal testing
• Drop shock testing

12. Iterations
Design optimization
The area of design optimization is where the
performance of a design can be made drastically
better than an initial naive implementation.
Topology optimization
Topology optimization is a mathematical method
which spatially optimizes the distribution of material
within a defined domain, by fulfilling given
constraints previously established and minimizing a
predefined cost function. For such an optimization
procedure, the three main elements are design
variables, the cost function and the constraints.

13. Manufacturing
Manufacturing processes
• Manufacturing Costs.
• Manufacturing Technique Capabilities and
availability.
• Desired Look and Feel of Product.
• Materials Needed for Production.
• Desired Surface Finishing of Product and
dimensional accuracy.
Maintenance

14. Design for Manufacturing / Assembly
Design for Manufacturing (DFM) is the process of
designing parts, components or products for ease of
manufacturing with an end goal of making a better
product at a lower cost. This is done by simplifying,
optimizing and refining the product design. Design for
Manufacturing (DFM) and design for assembly (DFA)
are the integration of product design and process
planning into one common activity. The goal is to
design a product that is easily and economically
manufactured.
For any business looking to make money and create
products that are profitable, DFM is vital for efficiency,
speed, and high rates of production. It is thought that
approximately 70% of the manufacturing costs of a
product derive from decisions made in the early design
stages, such as materials used or method of
manufacturing.

15. Design for Environment
Design for the Environment (DfE) is a design approach to reduce
the overall human health and environmental impact of a
product, process or service, where impacts are considered across
its life cycle.
• Reducing the use of materials, maximizing the number of replaceable
or recyclable components.
• Reducing toxic or polluting materials.
• Reducing emissions and waste in production processes.
• Increasing energy efficiency in phases of production and use.
• Increasing reliability and maintainability of the system.
• Respecting current legal constraints and evaluating future regulations
in preparation.

16. Design effort versus cost curve.

17. Reverse Engineering
It is the process of creating a product by a deep investigation to the shape
and the function of an existing production. The reverse engineering
process enables you to determine how a part was designed so that you
can recreate it.
The reverse engineering process is named as such because it involves
working backward through the original design process.
The challenge is to gain a working knowledge of the original design by
disassembling the product piece-by-piece or layer-by-layer.
Applications
• When the part malfunctions or breaks down completely, you replace
the component, not the whole device.
• Companies sometimes use reverse engineering to regain design data
on their own long-discontinued products. Even if the company still has
their paper blueprints, they may want to create a digital version of them
to make the plans easier to access and use.
• Design Improvement.
• Product analysis (to examine how a product works, what components it
consists of, estimate costs, identify potential)

18. Reverse Engineering
• When reverse engineering a mechanical product,
you start by analyzing the dimensions and
attributes of the product.
• Before disassembly, the reverse-engineering
team has to photograph the product up close
from the front and back to create a record of the
product composition.
• During disassembly, the design team removes
each part from the product, one after another.
The parts must be set aside for safekeeping and
organized in the order they were removed.
• With the various components removed from the
old product, the design team then draws up a list
of the materials of the product components.

19. 3D Scanning
3D scanning is the process of analyzing a real-world object or
environment to collect data on its shape and possibly its
appearance. The collected data can then be used to construct
digital 3D models.
After all the pertinent information has been gathered and
recorded, you can use this data to create computer-aided design
(CAD) drawings for subsequent analysis and development.

20. Material identification
•Color
•Texture
•Mechanical properties
•Spark test
•Electrical properties
•Thermal properties
•Magnetic properties
•Radiation - X-ray Fluorescence (XRF) analyser: The
device scans the metal material and identifies its key
elements. However, it cannot detect carbon and some
lighter elements and is not suitable for identification of
pure carbon steel materials.
•Optical Emission Spectroscopy (OES): This method
can detect almost all types of elements including
carbon and lighter elements and carbon steel.

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