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1. Aims of the Engineering Design Project The MFE3105 & IME3111 engineering design project is aimed at:

a) providing the student with the opportunity of experiencing an engineering design challenge;

b) fostering innovative design solutions where appropriate; c) providing the student with the experience of employing a systematic engineering

design approach to the generation of a solution for an engineering design problem; d) providing the student with the opportunity of employing relevant tools/methods

that are available to support the engineering design process; e) providing students experience of a ‘team-based’ design approach as typical in

industry. 2. Design Project Deliverables Each team should submit an A4 report having a maximum 40 pages including references but excluding drawings. This report should contain the following items:

a) A Product Design Specification (PDS); b) A list of tools / methods used, together with sample applications relevant to their

project, for the following key design activities (to be clearly included in the project report & presentation): x Problem analysis

x Solution synthesis

x Solution analysis

x Solution evaluation

c) Conceptual design sketches showing a minimum of four different working principles d) A minimum of one detailed, as deemed necessary, of each of the following:

x Morphological chart

x Function-means hierarchy/modular function deployment

x Rendered images of virtual 3D CAD models e) Different applications of synthesis tools, e.g. to create form use of synectics, to

generate working principles with morphological charts/SCAMPER. f) At least one assembly drawing of the whole solution concept to BS 8888:2008 with

relevant Bills of Materials and at least one sample drawing on geometric tolerance; g) Three examples clearly demonstrating that DFX principles have been catered for in

the proposed design solution especially when considering the mass production of the generated design solution;

h) Basic, as-developed costings of the solution selected; i) Arguments (in a suitable section of the report) in which students discuss their

opinion on using certain tools in a particular design activity, on the marketability of their design solution, etc.;

j) A section in the report (2 pages maximum) that benchmarks the solution developed with similar products, highlighting innovations of the solution;

k) Sample detailed design calculations: x E.g. calculation of stresses x Selection of a mechanical element (e.g. bearing, gear etc.)

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The report should be organized as follows: Executive summary of the project Introduction

� Problem Background � Problem Analysis � QFD, PDS

Part A - Conceptual Design

� Concept Synthesis � Analysis of Concepts � Evaluation of Concepts

Part B - Embodiment Design

� Embodiment Level Synthesis � Analysis of Embodiment Solutions � Evaluation of Embodiment Solutions

Part C - Detail Design

� Synthesis At Detail Level � Detailed Analysis & Evaluation

Part D - Marketing Aspects Part E – Detailed Engineering Drawings1 A professional report in pdf format with hyperlinks for a particular drawing/reference must be produced and submitted on a CD. In addition, one hardcopy of the report in A4 format must also be submitted. N.B.: Marks are allocated to reporting style and project branding. Each group should keep a A5 design logbook to keep a record of all the design activities carried out (e.g. group brain storming sessions, sketches, photos of similar products on the market, use of SCAMPER, synectics, calculations, meetings etc.) during the course of the project. It is important that the date when a particular design activity has been carried out is included in the logbook. Please note that the logbooks are non-returnable and are examinable material. In addition each team is to prepare and present:

x dynamic animation of the solution developed using 3D Studio Max or any other relevant software

x physical model(s) (e.g. made from cardboard, Styrofoam, Rapid Prototyping) generated during the conceptual design and embodiment design stages, for demonstrating the key design solution concepts. The Rapid Prototyping (RP) model should be not bigger than 250mm x 250mm x 30mm (L x B x H). Note that you can make use of software (e.g. PEPAKURA) which translates automatically 3D CAD models into development patterns;

1 Include only the drawings of the most critical components of the product, include detailed drawings of the overall concept + one sample drawing on geometric tolerance.

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x a 15 minute MS-PowerPoint presentation; x a 2 x A4 maximum Executive summary of the project; x an A1 poster that convey their   ‘design   solution   idea’   to   the   general   public   in   an  

attractive way (for samples, please contact Dr Ing. Philip Farrugia); x A 3mins YouTube presentation of the solution developed.

3. Design Project Management

a) The project will be carried out as a team under the direction of a team leader; b) Each team member will be responsible to report on a set of tasks. These tasks will be

assigned in week 1 of the project and are categorised as follows:

x tasks for Problem Analysis (including market research, QFD and PDS) x tasks for Solution Synthesis (including sketching, function-means

trees, synectics, morphological charts, synectics) x tasks for Solution Analysis (including 3D virtual and physical

modelling, DFX, FEA modelling, 3D animations) x tasks for solution evaluation (including design FMEA, costings,

marketability of the product) x tasks for project technical and public dissemination (including report

writing, MS Powerpoint presentation, poster, YOUTUBE presentation).

c) Attendance sheet will be taken on a weekly basis; d) Each team is to produce a final project report; e) Each team is to deliver a 15 minute MS-PowerPoint presentation; f) The team leader is to regularly co-ordinate project related issues with Prof Borg/Dr

Farrugia in the presence of the other team members; g) The team leader is responsible: to assign agreed roles to different team members; to

managing deadlines; to the submission of the final project report & MS-PowerPoint presentation; to booking of facilities e.g. CAD workstations etc.

h) Each team is to submit as one Appendix, a list summarizing the design review meetings made indicating the date and key decisions agreed at each meeting;

i) Each team should submit an endorsed (by all members) report clearly indicating deliverables (e.g. QFD, morphological chart assembly drawing, etc) for which the different team members were overall responsible. The list of who will be doing what by the end of the semester should be clearly communicated to Prof Borg/Dr Farrugia by end of February.

ALL TEAM MEMBERS ARE to endorse an Intellectual Property disclaimer which must be included in the report before the contents. 4. Design Brief Personal Transportation Systems

To provide an alternative/novel personal transportation means that is fully operational by human power. However it can in addition exploit renewable energy technologies to provide additional power where needed. At the same time, the device should offer unique selling points to different users.

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Basic Requirements:

� Should be lightweight yet durable � Should easily fold to be placed in car boots � Materials used should cater for different environmental conditions � Should be modular to adopt for different users (e.g. short, tall, heavy, male, female

etc.) � Should provide safety features both during day and night use � The selling price of the basic transportation system should be in the range of Eur

450 � Suitable for Malta's hilly terrain and roads + heavy traffic, yet suitable for overseas

markets � Emotionally pleasing � Can be mass produced � Should adhere to sustainable development principles

Unique Selling Points: Each group is to provide additional features to their transportation means that makes it attractive to a feasible market yet can be produced cost effectively. Group Target Audience: A Elderly (60+), occasional users B Individuals interested in carrying out physical exercises whilst using the

transportation system C Individuals with impaired mobility D Parents with two young children (<5 years) child E Users requiring speed and comfort for long distances F Industrial users requiring a transportation for carrying medium loads (e.g. mail)