Computer aided tolerancing (CAT) in the automobile industry is implemented by CAD tools. These tools analyze the manufacturability of complex assemblies with rigid single parts in an early stage to reduce the product development time and the cost for hardware prototypes. This paper proposes an approach to implement tolerance simulation for a compliant assembly, which includes manufacturing processes such as clinching, bolting and hemming by applying tolerance simulation tool. The fender- BIW system is simulated as a compliant–rigid system and the simulation model is applied to two production scenarios. The simulation results are compared with real measurement data, which demonstrates the efficacy of using simulation in early production as opposed to prototyping or other methods of design by showing the strong correlation between simulation results and as-built products.

Facing a rising competitive pressure, manufactures create advantages when they are able to offer customer-specific products to the conditions of a mass production article. Traditional configurators support the creation of personalized products from the elements of a modular product system, but are based on a pre-defined set of rules. The model based approach changes the environment of configuration from static configuration rules to the dependencies defined within the product's system model. So, by regarding target quantities of the user, the configurator identifies the optimal variant.

Renewable energy is increasingly used and promoted. In the UK, for example, large scale renewable energy farms have been used to supply electricity with great effect. Given the large number of homes, there is considerable impact to be made by small scale residential renewable energy systems. Despite solar panels being the most common form of residential renewable energy technology, only 4% of buildings in the UK support solar technology of any kind. For direct electricity generation, silicon-based photovoltaic (PV) arrays are the most utilised, and when used in a residential setting, they are typically mounted on the sloped roofs. This is where the problem lies. The technology comes with a high cost, and there is further financial burden of installation and maintenance, making solar energy inaccessible for many UK homeowners. This paper presents a research and design innovation project to make PV technology more accessible in the UK. Edge Solar, the innovative, affordable, new PV system concept for UK homes may become a promising solution to significantly improve the accessibility to the PV technology and renewable energy at the household level in the UK and beyond with further development and commercialisation.

This paper provides an overview of established approaches for function integration in additive manufacturing and critically compares their capabilities. One of the decisive factors is how functions and structures are addressed. This is necessary because function integration - among many others - affects material decisions and the manufacturing process chain. It is one of many reasons to rethink the product architecture and a way to support the design of resource-efficient products. Various strategies for function integration exist. However, there are currently no approaches in additive manufacturing that provide systematic support for early function integration.

A systematic literature review identified 21 unique approaches. All approaches were categorized according to their abstraction level within a product architecture and their design type to be supported. They were then compared on the basis of their categorization, design objective and strategy for function integration to allow for a better understanding of when to use the approaches in research and practice. Key findings and considerations for adapting function integration approaches to early design stages are presented. In addition, several research gaps were identified.

During a design process, designers are supported by several purposive product models. To enable designers to switch between them, researchers need to consider the linking of product models during their development. To assist researchers in doing so, the capabilities of a standardizing description approach, stances towards product models, was investigated. The results show that the description approach was able to identify indicators of linking possibilities by facilitating comparability. This is a step towards assisting researchers in considering the linking of product models systematically.

Engineering design research has largely focused on normative models of decision analysis based on small world causal frames where uncertainty can be resolved as probabilities or probability distributions. However, today we need to design solutions for our built environment that are sustainable, just, and able to adapt. Because of the scale and complexity of our world, designs that address sustainability, justice, and adaptability are dominated by unresolvable uncertainty. This requires large world frames and new engineering design frameworks and tools that provide a much broader and nuanced understanding of the impact of our engineering decisions. In this paper we propose that these tools will need to link quantitative and qualitative data and engineering judgment using narrative decision-making processes. To support this, we provide two examples where engineering decision-making is based in part on narrative processes. We then identify five research areas that require additional research to support large-world frames including (1) how can we create microcosms that enable transition between large- and small-world frames and (2) how engineers develop conviction to act using the narratives they create.

Due to the complexity of financial products, consumers with low financial literacy are left behind. However, few practical studies investigated the impact of digital advisory systems to improve customer experience. Configuration systems, as the most popular expert systems, have never been applied as a financial tool. In this study, we explore the application of configuration systems to educate consumers in achieving their financial goals. The results highlight multiple benefits from using the configurator, including greater financial literacy and improved individual financial decision-making.

Within the on-going ecological transition, mobility systems are considered as sociotechnical systems that raise several challenges for local authorities due to the different levels of decision, a complex stakeholder network and the numerous objectives to be dealt with. Designers are therefore seeking to develop new frameworks to support local authorities moving towards more sustainable mobility systems. Based on the French context, this study relies on an analysis of the regulation and an interview-based survey that depict the mobility design from the local authorities’ perspective. First, it investigates the objectives defined in the law and the difficulties met by local authorities. Then, it highlights the main political, organisational, and knowledge barriers for sustainable mobility. Finally, it proposes a set of recommendations to create a framework to better define and prioritise the objectives, ensure efficient planning and monitoring, clarify the interactions between actors, and enhance mobility plans.

Mental imagery is the experience of perceiving an object within one's own mind and is a subjective experience, leading to difficulties in the research and understanding of the phenomenon. This paper documents the development and verification of a framework for researching the elements of mental imagery. The framework was developed following a review of both psychology and design literature which signified three fundamental conceptual viewpoints of mental imagery: imagery modalities, dimensions of imagery ability, and imagery processes. The aim of this framework is to allow for structured research on mental imagery in any given research field. This is verified through discussion for the product design engineering discipline and provides a base for future work on this topic. The conclusions made in this paper reveal that mental imagery, and particularly visual mental imagery, is largely considered to be integral in design overlooking the different realities of designers and confirming a greater need to understand mental imagery experiences in product design engineering.

Sustainability is a key issue for manufacturing companies, which detail in their annual corporate social responsibility (CSR) reports how they plan to operationalise the seventeen sustainable development goals set by the United Nations in 2016. Design is deemed particularly relevant to integrate sustainability issues, and many design for sustainability (DFS) approaches have developed since the 1980s. However, the lack of understanding of the relationship between CSR and design prevents DFS approaches from enabling sustainability issues to be integrated in the design process in a relevant manner with the CSR strategy of a company. Consequently, we developed a mapping methodology in order to provide a better understanding of the CSR-design relationship. This mapping methodology consists in (1) identifying the relevant CSR goals that can be managed during the design process, (2) gathering information about the links between these CSR goals and the design process through semi-structured interviews, and (3) building a map representing these links. We started to apply our mapping methodology in an application case in the automotive industry. The first results of this application are presented in this article.

In order to meet the quality standards required in today's product development process, the designer must be able to draw on the knowledge contained in standards at all times. However, in today's digital work environment, these are usually only available in paper or PDF form. To support the designer during the product development process, a research project examine how knowledge from standards can be made available digitally and integrated into his working environment. This paper presents a concept with a RESTful service as a central knowledge base, which provides knowledge in the form of microservices. The implementation is carried out using welding assemblies as an example. To achieve the high-quality requirements and to implement them, the standard contents had to be prepared in a machine-interpretable and cross system way.

Small scale fabrication spaces have shown their potential to support our local supply chains during the collapse of many global supply chain networks at the onset of the COVID-19 pandemic. In anticipation of these spaces becoming more significant in local supply chains, it is increasingly important to reduce their environmental impacts. This work investigates the life cycle of small scale fabrication spaces by interviewing 18 participants from these spaces in the United States. Key insights from the interviews include the following: a) material selection, robust inventory management, and user support for material disposal are factors influencing optimal flow of materials and equipment through a fabrication space; b) lack of information from manufacturers and suppliers is a critical obstacle to achieve optimal use of materials and equipment, and informed decision making related to environmental sustainability and ethical labor practices; c) there are opportunities to take advantage of where financial and sustainability goals align; d) individual motivators for fabrication influences sustainable behaviors; and e) effective education about material and equipment use helps fabrication space users with more sustainable decision making.

Both industry and science point out the need to integrate PLM and ALM since products evolve from mechatronic to smart products. This paper investigates data management tasks fulfilled when creating or improving design. Particularly, the differences and commonalities in design evolution management of the software and hardware disciplines are considered.

This paper introduces a beta version of a hash function based tool, applying the software management mechanism on mechanical revision management.

With the paradigm shift towards Industry 4.0 and digitalisation, manufacturing engineers face several unexplored challenges; in the products for which they are designing production, in the equipment they are designing to realise production systems and in the digitalisation impact on engineering processes. Today's manufacturing system design processes are still based on traditional engineering methods and have difficulties to cope with increased complexity. The aim of this systematic literature review is to explore drivers and barriers to implement digitalisation in engineering processes from a socio-technical perspective. The identified general barriers were cyber security, lack of competence, lack of standards, large investments and resistance to change. For the engineering processes the main drivers were increased product complexity, servitisation, data driven design and engineering productivity, with the main barriers culture, excess amount of data, integration of tools. cyber security and data quality. The study shows the complexity of the challenge, and that it is not only the technology that is the top barrier. Further research is recommended to develop approaches of successful engineering digitalisation implementations.

Prior research has shown the importance of latent user needs for enabling innovation in early product development phases. The success of a product is largely dependent on to what extent the product satisfies customer needs, and latent user needs play a significant role in impacting the way the product or service unexpectedly delights the user. Complications arise because traditional need finding methods are not able to account for the nuances of latent user needs. A user's need is multidimensional while traditional methods are built on deductive reasoning. The traditional method isolates parts of the user's needs, only pointing to what is deducible within its search space. To address this, we introduce abduction as a way to broaden traditional need finding methods. From a logic based argument it is shown that abduction accounts for the dimensionality of user needs by integrating various traditional need finding theories using design knowledge to isolate the latent need. This theoretical development shows that latent need finding must go beyond a deductive focus, to developing methods that are able to conjecture with the deduced facts in order to abduce the latent user need.

Breast cancer is one of the most common cancer types among women, accountable for approximately 2.2 million new cases and 684,996 deaths globally in 2020. There are various screening methods to detect cancer early, and experts suggest that women should perform breast self-examination (BSE) once a month. Unfortunately, most women fail to do so even if they are aware of the risks and the importance of screening methods. The aim of this paper is to understand women's current behavior and experience with BSE and mobile BSE apps and to suggest several design dimensions for positive mobile BSE app experience by benefiting from positive technology. With this aim, three selected mobile BSE apps were used by a total of 24 participants for four weeks. A three-phase study was carried out to uncover women’s pre- during-, and post-usage experiences of BSE apps. The analysis revealed six headings under two themes: strategies, limitations, and emotions under BSE theme; and the needs, limitations, and benefits under Mobile Apps theme. Consequently, based on the findings, suggestions for design dimensions for BSE apps to better meet women’s needs by benefiting from levels of positive technology are made.

Bio-inspired design is an innovative methodology for transferring biological solutions into technical solutions, for example for the design of weight- and load-optimized components. Bio-inspired design therefore offers great potential for meeting the challenges of designing additively manufactured components, such as avoiding warpage, supporting structures and material minimisation. Nevertheless, apart from bio-inspired topology optimization tools, bio-inspired design is rarely used in industrial practice because for many companies the practical applicability up to the prototype is not obvious. The aim of this work is therefore a practical approach to the search for biological systems, analysis, abstraction and transfer of analogies. We apply bio-inspired design on the design of a microtiter plate manufactured by stereolithography, whose dimensional accuracy is impaired by warpage. Here, the venus’ flower basket, a deep-sea sponge, can serve as a model. It has a hierarchical structure of silicate needles whose elements are abstracted for bio-inspired transfer. We show and evaluate the transfer of different analogies using a prototype.

As the complexity of the systems increases, so does the complexity of designing a suitable engineering IT architecture. Challenges reach from the definition of required and consistent functionalities and interfaces to the evaluation, which combination of IT tools fulfils the required functionality, usability and interoperability in the best way. Thus, we provide a procedure, methodology and modelling support for the definition of functional and logical engineering IT architectures and their holistic evaluation. The approach is part of an overall procedure and demonstrated in an example.

This pilot study examines how design students comprehend collaborations with external organizations— the roles and involvement of different actors in a design process. The study looks at two undergraduate courses where a total of 33 design students collaborate with a municipality and governmental agency. Data focuses on the students' terminology in regard to the external organizations and is collected through questionnaires, voice recording, workshops and written assignments. The data analysis is both quantitative and qualitative, focusing on the word frequency and semantics of the terminology. The results show that the students were not used to working closely to external organizations. This is reflected in the prevalent use of the term “client” instead of “collaborative partner”. Not working closely with organizations nor users is reflected in the students’ inabilities to handle the complexities that emerge when working with multiple stakeholder and users. At the end of the paper, suggestions are made of ways to develop students’ comprehension of ways to involve external organizations and users in the design process.

In today's VUCA-World it is necessary to consider future requirements to develop change- and future-robust future products, especially regarding the increasing demand for sustainable solutions. In order to address this situation, upgradeability of modular products can be a solution. Considering that elements of modular products are used in several different products and over a long period of time, there is a need to act on this challenge. To uncover areas with a need for action, a systematic literature review on upgradeable and modular products was conducted. After resolving four fields of action and under consideration of the need for sustainable products, another systematic literature review examined the solution space of upgradable modular product architecture. In conclusion, several influencing factors on the upgradeable design of modular products could be identified, which are presented in this work.