Design Course for Mechanical Engineer

Lesson 1 • The Engineering Design Process

Covers the iterative design cycle from problem identification to validation. Anchors all subsequent design work in a structured, repeatable methodology.

Lesson 2 • Requirements and Constraints Definition

Teaches extraction and formalisation of functional, performance, and constraint requirements. Provides the specification baseline for all design decisions.

Lesson 3 • Design Thinking for Engineers

Introduces empathy-driven and user-centred design approaches adapted for mechanical contexts. Bridges human needs and technical specifications.

Lesson 4 • Concept Generation Techniques

Explores structured ideation methods including morphological analysis and TRIZ principles. Expands solution space before convergence on a design direction.

Lesson 1 • Orthographic and Multiview Projection

Covers first- and third-angle projection methods for representing 3D objects in 2D. Builds spatial visualisation skills essential for all technical drawing work.

Lesson 2 • Dimensioning and Tolerancing Fundamentals

Teaches size, location, and form dimensioning rules alongside basic tolerance assignment. Ensures drawings communicate manufacturing intent without ambiguity.

Lesson 3 • Section Views and Assembly Drawings

Covers full, half, and broken-out section views plus multi-part assembly drawing conventions. Prepares learners to document complex mechanical assemblies clearly.

Lesson 4 • Drawing Standards and Title Blocks

Reviews drawing sheet formats, title block content, and revision control practices. Aligns learner output with industry documentation and change management norms.

Lesson 1 • Feature-Based Part Modelling

Covers extrude, revolve, sweep, loft, and pattern features for solid part creation. Develops model organisation skills using feature trees and naming conventions.

Lesson 2 • CAD Drawing and Annotation Output

Covers generation of 2D drawings from 3D models including views, dimensions, and GD&T. Links parametric models to production-ready drawing documentation.

Lesson 3 • Assembly Modelling and Constraints

Teaches bottom-up and top-down assembly strategies with mate and constraint application. Enables creation of functional virtual assemblies with correct kinematic behaviour.

Lesson 4 • Design Intent and Model Management

Addresses parametric relationships, design tables, and configuration management for robust models. Ensures models remain editable and adaptable throughout the design lifecycle.

Lesson 1 • Surface Treatments and Coatings

Covers heat treatment, case hardening, anodising, and protective coatings for surface performance. Extends component life and enables use of lower-cost base materials.

Lesson 2 • Systematic Materials Selection Methods

Applies Ashby material index charts and performance index derivation to multi-objective selection. Enables quantitative, defensible material choices aligned with design constraints.

Lesson 3 • Polymers and Composites Selection

Introduces thermoplastics, thermosets, elastomers, and fibre-reinforced composites for structural use. Addresses anisotropy, creep, and environmental degradation in selection decisions.

Lesson 4 • Mechanical Properties of Engineering Materials

Reviews stress-strain behaviour, hardness, toughness, and fatigue properties across material classes. Provides the property vocabulary needed for informed selection decisions.

Lesson 1 • Fracture Mechanics and Damage Tolerance

Introduces stress intensity factors, fracture toughness, and crack growth rate concepts. Supports damage-tolerant design decisions for safety-critical mechanical components.

Lesson 2 • Fatigue Analysis and Endurance Limits

Covers S-N curves, endurance limit modifiers, and mean stress correction methods. Enables design of components subjected to cyclic loading for target service life.

Lesson 3 • Factor of Safety and Reliability

Introduces deterministic and probabilistic factor-of-safety approaches for design under uncertainty. Connects material variability and load uncertainty to component reliability targets.

Lesson 4 • Static Stress and Failure Theories

Reviews axial, bending, torsion, and shear stress calculations with combined loading analysis. Applies von Mises and Tresca criteria to predict yielding in ductile components.

Lesson 1 • Shaft Design and Analysis

Covers shaft sizing for combined bending and torsion, critical speed, and deflection limits. Integrates stress analysis and fatigue methods into a complete shaft design procedure.

Lesson 2 • Springs and Elastic Elements

Designs helical compression, extension, and torsion springs for stiffness and fatigue life. Extends to Belleville washers and rubber mounts for vibration isolation applications.

Lesson 3 • Fastener and Joint Design

Covers bolt preload, joint stiffness, and fatigue of threaded fasteners under combined loading. Addresses weld joint types, throat area, and shear and bending capacity.

Lesson 4 • Bearing Selection and Life Calculation

Applies dynamic load ratings and L10 life equations to select rolling-element bearings. Addresses mounting, fits, lubrication, and sealing for reliable bearing installations.

Lesson 1 • Additive Manufacturing Design Principles

Addresses support structure minimisation, build orientation, wall thickness, and lattice design for AM. Enables topology-optimised designs that exploit AM geometric freedom.

Lesson 2 • Casting and Forging Design Rules

Introduces draft angles, parting lines, wall thickness, and fillet requirements for cast and forged parts. Reduces tooling cost and defect risk through geometry-aware design.

Lesson 3 • Machining Process Design Considerations

Covers turning, milling, drilling, and grinding constraints that affect feature geometry and tolerances. Guides designers in specifying features that are machinable at minimum cost.

Lesson 4 • Sheet Metal and Forming Design

Covers bend radii, K-factor, hole-to-edge distances, and forming limits for sheet metal parts. Enables design of flat-pattern-correct parts that form without cracking or distortion.

Lesson 1 • Design Validation and Verification

Covers test plan development, prototype testing, and design review processes for formal validation. Closes the design loop by confirming that requirements are met before release.

Lesson 2 • Robust Design and Taguchi Methods

Uses parameter design, noise factors, and signal-to-noise ratios to minimise performance variation. Produces designs that perform consistently across manufacturing and use-condition variability.

Lesson 3 • Topology and Shape Optimisation

Introduces density-based topology optimisation and shape sensitivity for minimum-mass design. Produces organic, load-path-efficient geometries suitable for additive manufacturing.

Lesson 4 • Finite Element Analysis for Design

Covers mesh generation, boundary conditions, load application, and result interpretation for FEA. Enables simulation-driven design decisions and virtual validation of component strength.