Teaching Design in Context

As a result of recent curriculum revisions, the mechanical engineering faculty at the United States Military Academy teaches the formal design process “just in time” for students to apply the process to their capstone design projects. The design process consists of several phases and incorporates many engineering tools. During the initial offering of the course, Mechanical Engineering Design, instructors assigned students to capstone design teams early in the course. As the instructor taught the design process, team members applied the concepts to their capstone project. Based on instructors’ and students’ feedback, faculty revised the course structure to teach the design process in the context of a simple, in-class design project (design a portable illumination device) during the first half-semester. All in-class exercises were collaborative, hands-on experiences based on the project. To reinforce topics introduced in class and ensure all students develop a firm foundation in the design process, a separate common customer need (a device to store a West Point class ring) was the focus of all individual homework. Each student developed a design, built a prototype, and wrote an individual design report. Subsequent to formal design process instruction, students formed capstone teams and began their one and one-half semester capstone design projects. Results indicate that students more thoroughly understood the design process and its associated engineering tools allowing capstone teams to progress more efficiently through conceptual design; order parts, build prototypes, and test prototypes much earlier than the previous year; and enjoy a successful capstone experience.