MS3082: Design Lab

Course Instructor

Associate Professor Terry Steele

Course AIMS

Familiarize materials science students with concepts and digital tools in virtual design engineering.
Specifically:

1. Operate computer aided design (CAD) software towards parts sketching and geometric.
2. Draft part drawings in multiple views towards fabrication of outsourced prototypes.
3. Arrange multiple part assemblies, analyze assembly clearances, and create exploded views.
4. Evaluate and decide materials selections based on applied engineering function and associated loads.
5. Determine stress/strain measurements through simulations on part interfaces.
6. Exploit ‘Design Intent’ tools to yield multifunctional products that have optimized material properties under defined loads and stresses. To explain the differences observed in the data between the two grades of PS.

What are the underlying theories/concepts?

1. Geometric Modelling
2. Finite Element Analysis
3. Simulation in Engineering Analysis
4. Material Selection based on design intent
5. Prototype via FDM 3D printing
6. Iterative Virtual/P rototype Testing and Feedback

Intended Learning Outcomes

By the end of this course, you (as a student) would be able to:

1. Impart basic skills towards computer aided engineering, geometric modelling, parts mating, and ASTM-based drafting.
2. Establish and evaluate part engineering design with finite element modelling.
3. Prioritize features for prototype design, review, and application -related evaluation.
4. Demonstrate proficiency in a commercial CAD software widely used in engineering and manufacturing companies.
5. Manage and exhibit the design stages required for virtual and physical prototypes.
6. Apply advanced load/displacement simulations on part interfaces.
7. Design stress/strain simulations for refining prototypes to specific applications.
8. Convert virtual prototypes to physical models via 3D -printing.
9. Evaluate deficiencies between virtual prototype vs. physical prototypes.
10. Exhibit a CAD portfolio for resume building and future employment opportunities.
    

Course Content

1. Self-paced lectures on the concepts geometric modelling and 3D printings.
2. Self-learning tutorials that cover the basics of basic part modelling, drawings, and assemblies within CAD-based geometric modeling.
3. Simulations on part interfaces evaluating choice of materials and loads/displacement.
4. Demonstrate 5 advanced simulation tutorials of concerning stress/strains, thermal properties, pressure fitting, plastics flow, and injection molds.
5. Direct flow analyses to evaluate fluid and thermal dynamics.
6. Training in 3D printing to build and evaluate physical product prototypes build in CAD software.
7. Problem based learning group design collaborations solving real-world engineering scenarios.
8. Students will also be directed to Matlab tutorials for self-learning and usage scenarios.
   

Reading and References

As content is project-dependent, students are expected to seek references that are relevant to the projects assigned in the particular semester.

Supplemental Textbook:
Shetty, D., Product Design for Engineers. Cengage Learning, Boston, MA, 2016. ISBN: 9781133962045