Top 10 Steps of the Mechanical Design Process

Introduction

• Speaker: Dan Quiggle (DQ Design)
• Experience: 30+ years in mechanical design
• Background:
  • Early interest in mechanical design; built and repaired things from a young age
  • Work experience in motorcycle shop and various engineering firms
  • Founded own drafting business and consulting firm
  • Mentored FIRST Robotics high school team for 13 years
• Passion: Simple, elegant solutions to complex problems

Characteristics of a Good Designer

• Ability to visualize three-dimensional aspects and physics
• Freely consider all possibilities; avoid early fixation on an idea
• Convey ideas effectively, especially through sketching
• Be open to feedback and teamwork
• Experience and training add value
• Good combination: Designer with analytical skills
• Importance of administrative and people management skills for project management

Mechanical Design Process: Top 10 Steps

Step 1: Industry Comparisons

• Conduct thorough initial research, often starting with Google
• Look for commercial off-the-shelf solutions first
• Download available drawings and CAD models
• Reach out to non-competing companies in similar industries
• Note that some solutions are under non-disclosure agreements (NDAs)
• Effective initial research is key to custom solution planning

Step 2: Requirements and Preferences

• Define requirements by involving all stakeholders early
• Be mindful of real data, budgets, and schedules
• Initially conduct a study phase: gather general requirements, conceptual design, review market research, and estimate budget and schedule
• Requirements will likely evolve; flexibility is important
• Studies help eliminate unknowns and provide quality schedules and budgets

Step 3: Cost Effectiveness

• All factors like engineering, materials, manufacturing, safety, etc., affect decisions
• Good communication between finance and design is crucial
• Know when to sign off on a design based on risk and budget
• Simple solutions should form the foundation; upgrades can be added later

Step 4: Following the Loads

• Function and loads are primary considerations in design
• Use Finite Element Analysis (FEA) to identify stresses
• Avoid excessive use of materials which can add cost and complexity
• Free body diagrams can help with non-obvious load paths

Step 5: Functionality

• Prioritize functionality over conflicting factors
• Get feedback from operators of similar systems
• Build models or use 3D printing for process sequences testing
• Safety is critical; research OSHA guidelines
• Integrate tooling and make interfacing features accessible and intuitive

Step 6: Simplicity

• Seek the simplest solution for each design factor
• Round table discussions and brainstorming are valuable
• Encourage open-mindedness until budget and schedule constraints apply
• Avoid designing in isolation; iterate to address complexities

Step 7: Materials in Environment and Usage

• Consider environmental factors like corrosion, heat, cold, etc.
• Material selection affects cost, strength, durability, and aesthetics
• Design for lowest cost unless other factors (usage, aesthetics) dominate
• Stay updated on new products and methods
• Consider renewable materials and environmental impact

Step 8: Aesthetics

• Quality and look are important; impacts user perception
• Design should integrate proper coatings and tools
• Ensure safety considerations are part of aesthetic decisions

Step 9: Manufacturability

• Seek early and frequent feedback from manufacturing and installation teams
• Prepare good drawings and concepts before consulting them
• Multiple opinions can help balance design constraints
• Reliable partners in fabrication, assembly, and installation are invaluable

Step 10: Installation Sequencing

• Plan out the process from vendor sourcing to installation and maintenance
• Consider transport limitations (flatbed, bridges, etc.)
• Walk through the design with all stakeholders and confirm feasibility
• Use modular sequence assembly and installation procedure drawings

Conclusion

• This list is a high-level overview; many aspects follow industry standards
• All steps act in a feedback loop, often requiring iteration
• Open invitation for assistance and consulting
• Encouragement to like and subscribe to the speaker's channel