The work aims at the definition of a design methodology able to drive designers in the definition of product architectures, starting from rough information available at the conceptual design. The methodology identifies design guidelines useful for the development of product architectures optimized for a given target (i.e. assembly, cost). The methodology is based on domains which combine attributes related to a specific aspect of the target. The exploratory application of the methodology was performed to address the equipment installation of a civil aircraft for assembly/installation target.

Hackathons are short design events at which participants collaboratively progress through the entire design process. They pose opportunities for design research, but the existing research is limited, as is the understanding of design activity at hackathons. In our study, we summarize the hackathon design process of 10 interview participants from varying disciplines, levels of experience, and hackathon events. The summarized account reveals a decreased emphasis on the beginning phases of the design process, mainly problem definition, but an increased emphasis on the end, specifically the pitch portion of the event. These differences are mainly due to the limited time frame. We further assess the effect of time limitations at hackathons by comparing hackathons to other instances of design, emphasizing the impact of time constraints on iteration. We conclude our discussion with an exploration of the role expertise has on the design process by comparing the accounts of designers and developers.

This paper investigates the design and development of bio-inspired suture pins that would reduce the insertion force and thereby reducing the pain in the patients. Inspired by kingfisher's beak and porcupine quills, the conceptual design of the suture pin is developed by using a unique ideation methodology that is proposed in this research. The methodology is named as Domain Integrated Design, which involves in classifying bio-inspired structures into various domains. There is little work done on such bio-inspired multifunctional aspect. In this research we have categorized the vast biological functionalities into domains namely, cellular structures, shapes, cross-sections, and surfaces. Multi-functional bio-inspired structures are designed by combining different domains. In this research, the hypothesis is verified by simulating the total deformation of tissue and the needle at the moment of puncture. The results show that the bio-inspired suture pin has a low deformation on the tissue at higher velocities at the puncture point and low deformation in its own structure when an axial force (reaction force) is applied to its tip. This makes the design stiff and thus require less force of insertion.

Due to the falling costs of computational resources and the increasing potential of data acquisition, interest in digital twins, a virtual copy of the physical original, and their industrial application is increasing. Nevertheless, there is limited published work on how to support the process of physical to virtual twinning and what its key aspects are. The aim of this study is to present insights with regards to physical to virtual twinning gained from modelling projects in mechatronic product development. We conducted a survey and in-depth interviews with members of modelling projects. In the surveys and interviews we identified how physical products and virtual models were linked, which virtual models were used and which general challenges and key aspects are considered important by the project members. Our findings show that the key characteristics that pose challenges to modelling regarding physical to virtual twinning are model granularity, model validation, and model integration and interconnectivity.

The amount of new virtual reality input and output devices being developed is enormous. Those peripherals offer novel opportunities and possibilities in the industrial context, especially in the product development process. Nevertheless, virtual reality has to face several problems, counteracting reliable use of the technology, especially in ergonomic and aesthetic assessments. In particular, the discrepancies in perception between the real world and virtual reality are of great importance.

Therefore, we discuss these most important issues of current virtual reality technology and highlight approaches to solve them. First, we illustrate the use cases of VR in the product development process. In addition, we show which hardware is currently available for professional use and which issues exist with regard to visual perception and interaction. Derived from the depiction of a perfect virtual reality, we define the requirements to address visual perception and interaction. Subsequently we discuss approaches to solve the issues regarding visual perception and evaluate their suitability to enhance the use of virtual reality technology in engineering design.

Today high quality and low product development turnaround time are company-wide priorities. Quality supporting processes such as an effective risk management system shall support continuous business running and meeting the goals of an organization. In this paper, an approach is presented on how to integrate the product risk management in Product Lifecycle Management for configured products by definition of an additional software module and its implementation.

A refrigerant system (like that of a supermarket) is a complex system if we consider all the stakeholders throughout its lifecycle phases (use, maintenance, technological update, end of life). The lack of stakeholders' interaction during the design and other lifecycle stages of such a system generates issues and leads to sub-optimal system performances. We used the RID methodology to identify the main areas for improvement for these activities related to the refrigerant system. It is precisely designed to analyze, within the scope of activity, the major stakeholders' problems (user profiles) during lifecycle phases (use situations) to deduce areas for improvement (value buckets). Therefore, we built a process of interviews and data collection on existing practices to feed into a RID model. The first results are an archetypal description of the actors and problems encountered according to the lifecycle phases. The second part is a prioritized mapping of the areas to improve despite a certain number of known available solutions but proven insufficient.

Predicting the impact of changes in a design can be challenging, especially for complex designs. Margins are often built into the designs which can absorb the knock-on effect of such changes, erroneously allocating which can however, lead to propagation. A method for localising and sizing margins in an incremental design context is the Margin Value Method. This paper adapts MVM in the context of uncertainty in input specifications. It discusses possible ways to allocate them in a design such that undesirable effects of margins are minimised while preventing change propagation.

Adaptive façades (AF), unlike conventional façades, respond to their environment to reduce energy consumption while increasing comfort. The planning of AF presents architects and engineers with a variety of challenges. One central challenge is the specification of the right planning goals in the early phases. This paper identifies in a systematic literature review the main characteristics which were crucial in previous realizations of AF. Due to the comprehensive approach it provides a reference for the goal definition of subsequent projects and the development of further methodical support.

In methodical product development, numerous data are used and linked with each other, especially variant-related data. This paper presents a model-based solution for avoiding inconsistencies in the development of product families with many variants and extends it to modular lightweight design. In addition, the inconsistencies in methodical product development were classified and solution approaches were shown. Thus, inconsistencies can be avoided with the presented elaborated data model for an integrated product and process model based on the presented procedure.

The paper investigates the relationship between the forms through which products are represented and the outcomes of evaluations made by observers. In particular, the study focuses on perceived affordances of creative designs, meant as the capability of capturing original elements and corresponding functions, for products presented through static images or videos. Also thanks to the use of Eye Tracking, the experimental results show how dynamic effects that involve salient aspects of products, as well as creative features, are critical to observers’ capability of capturing design intentions.

The growing tendency for end users to get involved in the design and manufacturing phase of their own products has led to the proliferation of makers and prosumers. The tools available for this have been adapted to be used by non-specialized users who seek to meet their own needs and wants. Modular design offers a series of advantages directly related to the needs of current users, but which has hardly been used to benefit them. Instead, its development has geared towards aspects that are hidden to the consumer, such as flexible production.

This work presents a survey, part of a wider research, whose objective is to develop a methodological model for the prosumer to benefit from modular design. The survey was open for several months and was only aimed at makers, prosumers and designers. A dissemination plan was drawn up where the current communication channels of these users were taken into account. The results show what the current prosumer is like, what their needs are and how they relate to modular design. Finally, the conclusions provide information on how to develop a model proposal to ensure its correct usability and acceptance.

Twenty-three years ago, Sheard published a very well-known description of Systems Engineering roles. Each role represents and defines activities and tasks to be taken into account for performing Systems Engineering through the entire system life cycle. As today's more and more complex systems require different considerations and approaches, these activities and tasks have changed and thereby the description of the role model need to be updated. This work introduces the “Role Model for Systems Engineering Application”, which is adapted to today's circumstances, with the intention to give practitioners guidance in applying Systems Engineering. For this purpose, results from literature as well as from research projects and industrial applications experience were analyzed and combined to an updated role description.

This paper provides an overview of the state-of-the-art research about creative work and learning environments. We conducted a systematic literature search within the Scopus database and identified a total of 70 relevant sources discussing creative spaces within academic, practice, or other innovation environments. Among the included sources are 48 academic publications and 22 sources from company research and illustrative coffee-table books that are discussed separately. We analyse the academic sources regarding their theoretical contribution, as well as regarding their scope. Finally, the included sources are categorized according to three areas of interest: (1) the addressed space types for different creative activities, (2) abstracted requirements for creative spaces, and (3) concrete characteristics and configurations of a creative space. The results provide an in-depth insight into the current state of research on the topic of creative spaces. Practitioners, educators, and researchers can use the presented overview to investigate the possible impact of creative workspace design and to identify research gaps for conducting further research in the field.

Environmental issues such as climate change are leading to sustainability challenges for the aerospace industry. New materials such as composites allow significant weight reduction, which leads to a lower fuel consumption. However, composites involve complex processes and there is a lack of knowledge on their social and environmental consequences. Through two cases based on real aero-engines components, this paper shows that the weight savings provided by composites reduce significantly the CO2 emissions during flight which compensates the environmental drawbacks from production and recycling.

Laser Powder Bed Fusion is the most widespread additive manufacturing process for metals. In literature, there are several analytical models for estimating the manufacturing cost. However, few papers present sensitivity analyses for evaluating the most relevant product and process parameters on the production cost. This paper presents a cost model elaborated from previous studies used in a sensitivity analysis. The most relevant process parameters observed in the sensitivity analysis are the 3D printer load factor, layer thickness, raw material price and laser speed.

Set-Based Concurrent Engineering is commonly adopted to drive the development of complex products and systems. However, its application requires design information about a future product that is often not mature enough in the early design stages, and that it is not encompassing a service and lifecycle- oriented perspective. There is a need for manufacturers to understand, since the early design stages, how customer value is created along the lifecycle of a product from a hardware and service perspective, and how to use such information to screen radically new technologies, trade-off promising design configurations and commit to a design concept. The paper presents an approach for the multidisciplinary value assessment of design concepts in sub-systems design, encompassing the high-level concept screening and the trade-off of different design concepts, and enabling the integration of value models results into a Set-based Concurrent Engineering process. The approach is described through its application in the case study of the development of a subsystem component for a commercial aircraft engine.

Experiments that study engineering behavior in design often rely on participants responding to a given design prompt or a problem statement. Moreover, researchers often find themselves testing multiple variables with a relatively small participant pool. In such situations multiple design prompts may be used to boost replication by giving each participant an equivalent problem with a different experimental condition. This paper presents a systematic approach to compare given design prompts using a two-step process that allows an initial comparison of the prompts and a post-experiment verification of the similarity of the given prompts. Comparison metrics are provided which can be used to evaluate a level of similarity of existing prompts as well as develop similar problems. These metrics include complexity (size, coupling, and solvability), familiarity, and prompt structure. Statistical methods are discussed for post-experiment verification. Guidelines are provided for a post-experiment survey which may be used for an additional perspective of prompt similarity. The proposed approach is demonstrated using an experiment where two design prompts were used for within-subject replication.

Design pervades our world in variety and complexity that is difficult to grasp. Different disciplines and researchers take one or few perspectives to study, model, and try to understand design, why it fails and when it succeeds. However, without a comprehensive model, the value of such approaches is limited. We created a framework – the PSI (Problem, Social and Institutional Spaces) framework – that includes several models, ranging from simple to complex, networked, and hierarchical or recursive that can be used to model all design scenarios. In what follows, we demonstrate the network version of this framework, how it is used, and what insight it can present. The diversity of situations we present, mergers and acquisitions of companies, collaborations between industry and university, large multi- organizational projects, and a very complex project, as well as other cases we do not present here, confers the validity of utility and potential of the PSI framework.

As the diversity of customer needs increases within the aerospace industry, so does the need for improved design practices to reduce quality issues downstream. When designing new products, design engineers struggle with applying tolerances to features, which often leads to expensive late design iterations. To mitigate this, one aerospace company is looking to reuse tolerance deviation data yielded during manufacturing in design. In the long term these data could provide the basis for a Digital Twin that can be used for improved product development. This article explores how data from production are used today, what issues prevents such data from being exploited in the design phase, and how they potentially could be used for design purposes in the future. To understand the current situation and identify the untapped potential of production data in design, an interview study was conducted in conjunction with a literature review. In this paper the current situation and primary barriers are presented and a possible path for further research and development is suggested.