Understanding the engineering design process

The engineering design process is a structured, iterative method for solving problems: define the problem, research it, brainstorm solutions, plan, prototype, test, improve, and communicate the results. Engineers and designers use it to turn ideas into products that solve real problems for a target audience.

The structure matters because most new products fail—and the most common reason is that nobody needs them. A defined decision-making process during product innovation and development keeps product development teams focused on solving a genuine problem rather than just shipping a clever idea.

This article explains what the engineering design process is and provides a step-by-step guide for using it on your next product.

What is the engineering design process?

The engineering design process is an iterative process of brainstorming, troubleshooting, and developing a product to solve a specific problem. The steps encourage open-ended problem-solving and learning from failure.

When product designers use the engineering design process, they apply engineering experience, industry knowledge, and technology to design and build solutions for specific problems.

While the process follows a defined pattern, it’s iterative by design. Some steps may be completed out of order or repeated to eliminate issues or examine areas of concern. It’s commonly used on any project that requires designing, building, and testing a product.

The principles of good engineering design

There are multiple variations of the engineering design process, but good engineering design rests on the same underlying principles:

• Engineering is a process with defined steps to provide the best solution to a specific problem.
• The design process is iterative—some steps are repeated or carried out in a nonsequential order.
• Analyzing and evaluating different solutions is essential for identifying strengths and weaknesses and meeting the design specifications.
• Failure is expected and used as a learning tool throughout.

Why is engineering design important for innovation?

The engineering design process exists to create products that meet the needs of a target audience. By following a defined path from problem to solution, engineers can research multiple ideas and determine which solution is most viable.

The process is iterative and flexible enough to encourage creativity. That combination produces innovative thinking and multiple solutions to complex problems.

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Benefits of the engineering design process

The engineering design process turns ideas into practical solutions. Its structured approach brings several benefits.

Improved product quality

The process follows specific steps to ensure every possibility is explored. Because it promotes problem-solving, iteration, and extensive testing, the most promising ideas bubble to the top for further development.

Collaboration

Tactics like brainstorming, group thinking, prototyping, and testing encourage collaboration between various stakeholders, including:

• Engineers
• Designers
• Manufacturers

Multiple experts working toward a common goal can eliminate issues or shortfalls before a product reaches customers.

Cost savings

Working with multiple ideas and identifying design flaws early greatly reduces the risk of a flawed product going all the way to completion. Testing throughout the process addresses errors in real time and keeps rework to a minimum.

Faster time to market

Repeating steps might sound like it would prolong development. In practice, identifying potential issues early reduces overall project duration, because less time goes into revisions later on.

Increased innovation

The engineering design process centers on creative thinking to find the best solutions to a specific problem. It’s typically carried out by multiple team members and treats failed attempts as stepping stones to a better solution.

A step-by-step guide to the engineering design process

The engineering design process is versatile, so it can be adapted to include fewer or more steps depending on the project. Remember it’s iterative—steps may be repeated as needed.

These steps cover the basics.

1. Define the problem you want to solve with your product

To develop an effective solution, clearly define the problem, any known constraints to solving it, and the end user’s needs.

Once you’ve identified the problem, clarify why it’s a problem and how large the audience for a solution is. Examine the problem from different viewpoints to make sure you understand its impact.

2. Ask questions and conduct relevant research

Dig deeper into the cause of the problem and whether potential solutions already exist. Ask these questions to guide your research:

• Why is this a problem?
• Why is it important to develop a solution to this problem?
• Who can the right solution help?
• Do solutions already exist? If so, why aren’t they being used, or how is our solution going to be better?
• Are there financial, legal, technical, or other restraints that could introduce new requirements for the solution?

3. Imagine possible solutions

Once you have the information to hand, brainstorm a list of possible solutions.

Generate as many ideas as possible, including unconventional ones. Involve industry experts, employees, experienced professionals, and other stakeholders in the brainstorming process to get multiple perspectives.

Combine all prospective solutions into a list for consideration.

4. Plan

Examine your list and research each proposed solution. List the pros and cons of each to rank the list in order of viability.

Eliminate solutions that are less viable or have too many flaws. Keep narrowing down until you arrive at the ideal solution.

Draw up a product design that solves the problem while addressing constraints and potential issues that may arise during the build.

5. Develop a prototype

Use your plan to create an early prototype of your product. The prototype should be cost-effective and can be made from different materials than the final product. It’s common to leave finishing touches off early prototypes so you can concentrate on the overall concept.

6. Test

Once you’ve created a usable prototype, run a series of tests to determine how well the product works—not only in normal operating conditions but also under extra stress.

Use the tests to simulate real-life scenarios. Even a functional prototype may not meet all your expectations. Note where the product falls short so you can improve it in subsequent iterations.

7. Make improvements

If the prototype fails completely, you have choices to make. You can revisit some of your earlier solutions or brainstorm ideas that eliminate the problems.

If your prototype didn’t meet every expectation, it can still be called a success. Use your notes to investigate where it under-performed and consider ways to fix those specific issues.

Improve your existing prototype or design a new iteration, then test again. Repeat the testing and improvement loop as many times as needed to yield the best possible product.

8. Communicate the results

The final stage is sharing your results. Create reports, presentations, and displays as needed to demonstrate how your product works and why it’s the best solution to the problem at hand.

Your documentation shares the product’s value with stakeholders and enables the finished product to be manufactured to the required standards. You may need to present the results to managers, engineers, board directors, shareholders, and even potential customers.

Once you have the go-ahead from all decision-makers, you’re ready to build.

Engineering design process examples

The engineering design process can be applied to a broad range of products. Let’s look at a couple of examples.

Developing a new gaming app

Imagine you’d like to develop a new app in the form of a game.

1. Define the problem: What problem will your app solve? Boredom? Lack of mental stimulation? Kids needing to be kept occupied? Parents needing to unwind?
2. Research: How widespread is this problem? Find out what games already solve it. Do they do it well, or is there a gap in the market for a game that does it better? Are there any good reasons not to develop such a game?
3. Imagine solutions: With your team and relevant stakeholders, brainstorm as many game ideas as possible. Let your imagination run riot.
4. Plan: List the pros and cons of each idea. Narrow down the list and plan a design for the one you decide to pursue.
5. Develop a prototype: The prototype doesn’t need to be complex—just enough to give testers an idea of the game and how it solves the problem you pinpointed.
6. Test: Find testers to try out your prototype game and gather feedback from them.
7. Make improvements: Adjust your prototype based on tester feedback. Return to the testing step and keep repeating these two stages until you have the best possible version of the game.
8. Share results: Create a report or presentation to communicate your decisions to stakeholders and make the case for your solution. Once your game idea is signed off, it’s time to start developing the actual product.

Creating a kitchen appliance

Plenty of gadgets promise to make life easier in the kitchen, and people always seem to want more. Imagine you’d like to be the next big thing in kitchen appliances.

1. Define the problem: What problem will your appliance solve? Will it save time, effort, or money—or all three? Will it reduce mess, increase safety, or make it easier to cook good meals?
2. Research: How widespread is the problem you’re trying to solve? Find out what appliances already address it. Do they do it well, or is there a gap in the market for a better appliance? Are there any good reasons not to create it?
3. Imagine solutions: Brainstorm as many appliance ideas as possible. Be creative—nothing is impossible at this stage.
4. Plan: Weigh the advantages and disadvantages of each idea. Narrow down the list and plan a design for your favorite one.
5. Develop a prototype: It doesn’t need the same materials or full functionality as the final appliance. It just needs to give testers an idea of the appliance and how it solves a particular problem in the kitchen.
6. Test: Gather feedback from people willing to test your prototype appliance.
7. Make improvements: Adjust your prototype based on tester feedback. Return to the testing step and repeat these two stages until your prototype receives no more negative feedback.
8. Share results: Tell your stakeholders about the appliance through a report or presentation and make the case for your solution. Once it’s signed off, you can start production.