Product Design and manufacturing ppt how it works .pptx

PDM

1. Product Design Innovation, Functionality, and User Experience T. JayaDeep 25/07/2025

2. What is Product Design? More than just aesthetics; it's about solving problems and creating value. Definition : The process of creating new products to be sold by a business to its customers. It involves understanding user needs, developing concepts, and refining designs for manufacturing. Focus in Mechanical Engineering : Integration of engineering principles, materials science, manufacturing processes, and user-centric considerations. eerin

3. Why is Product Design Crucial? ● Competitive Advantage: Differentiates products in the market . ● Market Success: Directly impacts sales and profitability. ● User Satisfaction: Meets user needs, leading to loyalty . ● Reduced Costs: Efficient design can lower manufacturing and warranty costs. ● Innovation: Drives technological advancement and new solutions.

4. The Product Design Process - An Overview Stages : 1. Problem Identification & Research 2 . Concept Generation 3 . Detailed Design & Analysis 4 . Prototyping & Testing 5 . Manufacturing & Production 6 . Launch & Post-Launch Evaluation

5. Objective: Define the problem to be solved and identify user needs. Problem Identification & Research - Understanding the Need Activities: ○ Market Research (Surveys, Focus Groups, Competitor Analysis) ○ User Research (Interviews, Observations, Personas) ○ Defining Product Requirements (Functional, Non-functional) ○ Identifying Constraints (Cost, Time, Technology)

6. User-Centric Design (UCD) ● Key Principle: Design with the end-user in mind. ● Importance: Ensures the product is intuitive, effective, and enjoyable to use. ● Methods: User journey mapping, empathy maps, usability testing. ● Example: How a user interacts with a mechanical device (e.g., a hand tool).

7. Stage 2 : Concept Generation - Brainstorming Solutions Objective: Generate a wide range of potential design solutions. Techniques: ○ Brainstorming & Mind Mapping ○ Sketching & Ideation ○ SCAMPER Method (Substitute, Combine, Adapt, Modify, Put to another use, Eliminate, Reverse) ○ TRIZ (Theory of Inventive Problem Solving)

8. Concept Selection - Refining Ideas Objective: Evaluate and select the most promising concepts. Methods: ○ Pugh Matrix (Decision Matrix) ○ Weighted Scoring ○ SWOT Analysis (Strengths, Weaknesses, Opportunities, Threats)

9. Stage 3 : Detailed Design & Analysis - Bringing Concepts to Life Objective: Translate selected concepts into detailed engineering designs. Tools: ○ CAD (Computer-Aided Design) Software (SolidWorks, AutoCAD, CATIA, Creo) ○ CAM (Computer-Aided Manufacturing) ○ CAE (Computer-Aided Engineering) - FEA (Finite Element Analysis), CFD (Computational Fluid Dynamics)

10. Material Selection - The Backbone of Mechanical Design Importance: Directly impacts performance, cost, weight, and manufacturing process. Factors: ○ Mechanical Properties (Strength, Stiffness, Toughness) ○ Physical Properties (Density, Thermal Conductivity) ○ Chemical Properties (Corrosion Resistance) ○ Manufacturing Suitability ○ Cost & Sustainability

11. Manufacturability (DFM) & Assembly (DFA) Design for Manufacturability (DFM) : Designing products that are easy and cost-effective to produce. ○ Minimizing parts, standardizing components, choosing appropriate processes. Design for Assembly (DFA): Designing products that are easy and efficient to assemble. ○ Reducing assembly steps, simplifying mating features, using common fasteners.

12. Engineering Analysis - Predicting Performance Finite Element Analysis (FEA ): Simulating stress, strain, deformation, and thermal behavior. Computational Fluid Dynamics (CFD): Analyzing fluid flow, heat transfer, and related phenomena. Kinematic & Dynamic Analysis: Simulating motion and forces in mechanical systems. Benefits: Optimize design, prevent failures, reduce physical prototypes.

13. Stage 4: Prototyping - Turning Digital into Physical Objective: Create physical models to test and validate the design. Types of Prototypes: ○ Concept Prototypes: Basic models to test form and fit. ○ Functional Prototypes: Working models to test performance. ○ Visual Prototypes: High-fidelity models for aesthetic evaluation. Methods: 3D Printing (Additive Manufacturing), CNC Machining, Rapid Prototyping.

14. Testing & Validation - Ensuring Robustness Objective: Verify that the product meets requirements and performs as expected. Types of Testing: ○ Functional Testing (Does it work?) ○ Performance Testing (How well does it work?) ○ Durability Testing (How long will it last?) ○ Environmental Testing (Temperature, humidity, vibration) ○ Usability Testing (Is it easy to use?)

15. Stage 5: Manufacturing & Production - Scaling Up Objective: Transition from prototype to mass production. Considerations: ○ Tooling and Fixture Design ○ Production Line Setup ○ Quality Control (QC) and Assurance (QA) ○ Supply Chain Management ○ Automation and Robotics

16. Launch & Post-Launch Evaluation - Continuous Improvement Objective: Introduce the product to the market and gather feedback. Activities: ○ Marketing & Sales ○ Customer Support ○ Performance Monitoring (Warranty claims, field failures) ○ User Feedback Collection ○ Iterative Improvements and Next Generation Products

17. Key Principles of Good Mechanical Product Design Functionality: Meets its intended purpose effectively. Reliability: Performs consistently over time. Safety: Protects users from harm. Durability: Withstands wear and tear. Maintainability: Easy to repair and service. Cost-Effectiveness: Achieves design goals within budget. Aesthetics/Ergonomics: Visually appealing and c

18. Tools and Technologies in Modern Product Design CAD/CAM/CAE Software: Essential for modeling, analysis, and manufacturing. 3D Printing/Additive Manufacturing: Rapid prototyping and custom parts. Simulation Software: Predicting product behavior under various conditions. Product Lifecycle Management (PLM) Systems: Managing product data throughout its lifecycle. IoT (Internet of Things) for Product Monitoring: Real-time performance data and predictive maintenance.

19. Case Study : Smart Phone

20. Challenges in Mechanical Product Design ● Balancing Conflicting Requirements: Performance vs. Cost vs. Aesthetics. ● Technological Obsolescence: Keeping up with rapid advancements. ● Supply Chain Volatility: Sourcing materials and components. ● Regulatory Compliance: Meeting safety and environmental standards. ● Intellectual Pro perty (IP) Protection: Safeguarding innovative designs. ● Managing Complexity: Integrating diverse systems and components.

21. Future Trends in Mechanical Product Design Generative Design & AI: Automated design optimization. Sustainable Design: Cradle-to-cradle approach, circular economy. Smart Products & IoT Integration: Connectivity and data-driven insights. Advanced Materials: Composites, metamaterials, smart materials. Digital Twins: Virtual replicas for real-time monitoring and simulation. Human-Robot Collaboration (Cobots): Designing for interaction.

22. The Role of the Mechanical Product Designer Skills: Creativity, analytical thinking, problem-solving, technical proficiency, communication. Responsibilities: From concept ideation to production support. Interdisciplinary Collaboration: Working with electrical engineers, industrial designers.

23. Conclusion The Power of Thoughtful Design Product design is a multidisciplinary, iterative process essential for creating successful, user-centric, and innovative mechanical products . Final Message: Good design is not just about how something looks, but how it works, how it's made, and how it impacts people's lives. It's the fusion of art and science.

24. Thank You