The conceptualization of new designs involves several phenomena. Research indicates that new ideas are rarely, if ever, wholly novel ideas. Instead, new ideas are formed from combinations of existing ideas, supported by synthesis, transformation, analogy, morphing, and replacement. Moreover, while much research has explored the negative implications of fixation from examples and stimuli, there exists an emerging need to study potentially positive effects of inspirational cases. Many works have studied designers' exploratory practices of solution spaces revealing active discovery and investigation of similar solutions as analogies. These exploratory practices enable designers to better understand a problem and inspire new solutions. In this work, the authors demonstrate directed use of design principles as design inspiration to improve outputs of the ideation process. Specifically, this work focuses on design principles for the particular domain of additive manufacturing, but the results suggest avenues to generalize the process with design principles from different areas. In this study, the authors created a set of physical cards to communicate a derived set of design principles. Each card is comprised of three main elements: (i) a textual description of the principle, (ii) a simplified visual representation of the principle, and (iii) an example of a real world application of the principle. Participants (N = 61) were allotted two equally timed rounds to ideate solutions for a standard design problem and given a set of the design principle cards as an intervention between the first and second rounds. Idea quantity, quality, and novelty were measured per round. Results showed no significant change in quantity-an improvement over the established trend of a decline over consecutive sessions without stimulus. Significant improvements in quality and novelty, however, were measured, indicating that the cards did assist designers in ideation. The results demonstrate that the principles, formatted as discussed, provide real avenues to arrive at innovative solutions.

Design-by-analogy is a growing field of study and practice, due to its power to augment and extend traditional concept generation methods by expanding the set of generated ideas using similarity relationships from solutions to analogous problems. This paper presents the results of experimentally testing a new method for extracting functional analogies from general data sources, such as patent databases, to assist designers in systematically seeking and identifying analogies. In summary, the approach produces significantly improved results on the novelty of solutions generated and no significant change in the total quantity of solutions generated. Computationally, this design-by-analogy facilitation methodology uses a novel functional vector space representation to quantify the functional similarity between represented design problems and, in this case, patent descriptions of products. The mapping of the patents into the functional analogous words enables the generation of functionally relevant novel ideas that can be customized in various ways. Overall, this approach provides functionally relevant novel sources of design-by-analogy inspiration to designers and design teams.

Many natural systems have inspired the design of engineering artifacts. Example systems include a broad array of products inspired by pseudo-fractal structures found in nature, including bronchial tubes, watersheds, lightning, and leaf veins. Notably, these systems all resolve a volume-to-point flow problem, i.e., diffusive transportation of heat, energy or fluid into a single flow channel from an initial dispersal throughout a substrate volume (coalescence). Flow diffuses slowly throughout the bulk of the substrate medium towards channels. Once in the channels, flow proceeds rapidly towards the sink. These channels are branched and converge at a single point. Several engineering design problems require a volume-to-point flow solution, e.g., the internal conductive cooling of a microchip. This work introduces a novel geometry-based transport analysis, referred to as path length analysis, for evaluating the performance of systems designed for volume-to-point flow. The analysis is inspired by two principles. First, diffusive flow tends to follow the “path of least resistance.” Second, the effort required to diffuse material or energy along a path is proportional to the length of the path. Novel channel configurations may be developed using these two principles. These configurations have a pseudo-fractal type structure and are significantly more efficient than the state-of-the-art for cooling problems such as the conductive cooling of a microchip. An extensive finite element analysis confirms the performance for the example of microchip cooling. The primary results include (1) path length optimization leads to high performing structures with a ‘natural’ appearance, and (2) path length analysis facilitates a new understanding and design tool for analyzing volume-to-point flow problems.

Design-by-analogy is an effective approach to innovative concept generation, but can be elusive at times due to the fact that few methods and tools exist to assist designers in systematically seeking and identifying analogies from general data sources, databases, or repositories, such as patent databases. A new method for extracting analogies from data sources has been developed to provide this capability. Building on past research, we utilize a functional vector space model to quantify analogous similarity between a design problem and the data source of potential analogies. We quantitatively evaluate the functional similarity between represented design problems and, in this case, patent descriptions of products. We develop a complete functional vocabulary to map the patent database to applicable functionally critical terms, using document parsing algorithms to reduce text descriptions of the data sources down to the key functions, and applying Zipf's law on word count order reduction to reduce the words within the documents. The reduction of a document (in this case a patent) into functional analogous words enables the matching to novel ideas that are functionally similar, which can be customized in various ways. This approach thereby provides relevant sources of design-by-analogy inspiration. Although our implementation of the technique focuses on functional descriptions of patents and the mapping of these functions to those of the design problem, resulting in a set of analogies, we believe that this technique is applicable to other analogy data sources as well. As a verification of the approach, an original design problem for an automated window washer illustrates the distance range of analogical solutions that can be extracted, extending from very near-field, literal solutions to far-field cross-domain analogies. Finally, a comparison with a current patent search tool is performed to draw a contrast to the status quo and evaluate the effectiveness of this work.

Prototyping may be simultaneously one of the most important and least formally explored areas of design. Over the last few decades, designers and researchers have developed many methodologies for ideation, product architecture, design selection, and many other aspects of the design process. However, there have been relatively few methodologies published regarding the efficient and effective development of prototypes for new products. This research explores a methodology for enhancing the prototyping process. It is founded on extensive literature review of the best practices of engineering prototype development. These findings have been aggregated and form the foundation of a methodology for formulating prototyping strategies. This methodology has then been experimentally evaluated in a controlled design environment, and its effect on the performance of prototypes has been demonstrated. The method consists of a set of guiding questions with corresponding flowcharts and foundational equations that assist the designer to make choices about how to approach the prototyping process in an efficient and effective manner.

This work seeks to introduce and evaluate effects of a novel method for designing prototyping strategies. This newly developed heuristics-based tool guides designers in planning a prototyping strategy based on answers to Likert-scale questions that embody empirically validated heuristics. We created this tool to augment prior work in the development of prototyping planning methods. The new tool guides designers through six critical prototype strategy choices: (1) How many concepts should be prototyped? (2) How many iterations of a concept should be built? (3) Should the prototype be virtual or physical? (4) Should subsystems be isolated? (5) Should the prototype be scaled? (6) Should the design requirements be temporarily relaxed?We assessed the new planning tool in two environments: (1) a controlled experiment in which volunteers completed a prototyping design challenge, and (2) a capstone design class with a diverse range of open-ended sponsored design projects. In both cases, students received training for the method and then employed it in their own efforts.In our study the new tool caused student teams to employ significantly more efficient and effective prototyping strategies, such as prototyping early and often. The results indicate a higher functional performance of prototypes from groups using the new planning tool compared to control groups. This paper describes the new prototyping strategy planning tool, details both sets of experiments, and discusses results.

Design-by-analogy is a growing field of study and practice, due to its power to augment traditional concept generation methods by expanding the set of generated ideas using similarity relationships from solutions to analogous problems. A new method for extracting functional analogies from data sources has been developed to assist designers in systematically seeking and identifying analogies from general data sources, databases, or repositories, such as patent databases. This search engine and design-by-analogy facilitation tool uses a functional vector space model to quantitatively evaluate the functional similarity between represented design problems and, in this case, patent descriptions of products. Document parsing algorithms are developed to reduce the patent text to key functions and solved conflicts using Zipf’s law to reduce the words within the patents into the applicable functionally analogous terms, providing a mapping process for functional-based search. The mapping of the patents into the functional analogous words enables the generation of novel ideas that can be customized in various ways, providing potentially relevant sources of design-by-analogy inspiration. This paper presents a controlled experiment designed to evaluate the search engine efficacy during the conceptual ideation process. The two treatments explored are the effect of including analogous patents during ideation, and the effect of functionality level. The tool efficacy during concept generation is shown to increase novelty of generated solutions, while there is no significant change in the quantity of generated solutions.

Well developed innovation processes are essential components for continued success of product and systems design throughout industry. Such processes build upon research advancements in innovation techniques and methods. To create such techniques and methods, studies are needed to examine the current state-of-the-art, as well as the corresponding teaching of such innovation processes in higher education. This paper contributes to this effort by studying a specific group of innovation researchers, teachers, and practitioners. The study was created to probe this group of leaders in the engineering design domain using technical, demographic, and short answer questions. Various analysis methods are used to obtain a fundamental view of the answers to these questions with respect to the demographics of the participant group. Two deductive analysis methods are used, in addition to an inductive approach, consisting of a correlation analysis to compare responses to questions and understand trends across the participants. Results from the analyses emphasize the current perceptions of innovation by the participants and opportunities to refine research in improving innovation practices.

Designing an attachment structure that is both novel and meets the system requirements can be a difficult task especially for inexperienced designers. This paper presents a design methodology for concept generation of a "parent/child" attachment system. The "child" is broadly defined as any device, part, or subsystem that will attach to any existing system, part, or device called the "parent." An inductive research process was used to study a variety of products, patents, and biological examples that exemplified the parent/child system. Common traits among these products were found and categorized as attachment principles in three different domains: mechanical, material, and field. The attachment principles within the mechanical domain and accompanying examples are the focus of this paper. As an example of the method, a case study of generating concepts for a bridge mounted wind energy harvester using the mechanical attachment principles derived from the methodology and TRIZ principles derived from Altshuller's matrix of contradictions is presented.

Energy harvesting is a promising and evolving field of research capable of supplying power to systems in a broad range of applications. Energy harvesting encompasses many distinct technologies, including photovoltaic panels, wind turbines, kinetic motion harvesters, and thermal generators. Each technology utilizes different processes to transform energy from the environment into usable electrical energy. As such, there are many analogous functions and processes that are common or similar across the various domains. To leverage and understand these functions and processes, functional modeling approaches are needed to identify these similarities and functions ripe for innovation in new systems. This paper describes a method for modeling the functional architectures of a sample set of energy harvesters, using a functional common basis from the literature. Vector space analysis is used to identify patterns and correlations in the use of functions across different products and energy-harvesting domains in the sample set. The resulting analysis indicates that systems in the same domain usually have very similar function structures, differing only by the addition or removal of a few driving or supporting functions. Systems in different domains also typically have similar structures, with the substitution of different material and energy flows into the system. A generalized functional model for energy harvesting is described, along with possible design ramifications and key opportunities to innovate. Several recommendations are given for the continued development and improvement of the functional common basis and, more generally, functional modeling methodologies. These include improved standardization and explanation of abstract functions, such as blending with the environment, and of organizational conventions to improve consistency.

In response to the call for multi-functional products, we have developed several relevant ideation techniques. These techniques are tailored for design of transformers- devices with multiple functional states. In this paper, we present significant advancements in transformational design. Primarily, we introduce a method to enhance quality, novelty, and feasibility (QNF) of design solutions. The method is used to classify design problem context and suggest pursuit of one of the two following device archetypes, transformer or monomorph-devices with a single functional state. The Indicators method is associated with a significantly increased probability of producing a design problem solution with higher QNF than a control (standard) design method. The claim that this method is accurate, its results are repeatable, and usage thereof enhances QNF is supported by a network of experiments and analyses. Statistical analysis is used to establish the accuracy, precision and repeatability of the method. Industry-standard qualitative methods, including inter-rater reliability analysis, demonstrate that usage of the Indicators method enhances design concept QNF. Concurrent minor analyses highlight the novelty of transformable designs; and some positive psychological effects of using the method. Additionally, the contextual (archetype) indicators have shown implicit promise as a core element for future research into ideation methods.

Many natural systems that transport heat, energy or fluid from a distributed volume to a single flow channel exhibit an analogous appearance to trees (examples include bronchial tubes, watersheds, lightening, and blood vessels). Several authors have proceeded with analytical methods to develop fractal or pseudo-fractal designs analogous to these natural instances. This implicates an implicit belief in some designers that there is an optimal attribute to this ‘tree-like’ appearance. A novel explanation for the appearance of these systems is presented in this paper. Natural systems follow the path of least resistance; or in other words, minimize transport effort. Effort is required to overcome all forms of friction (an unavoidable consequence of motion). Therefore effort minimization is analogous to transport distance (path length) minimization. Effort due to friction will be integrated over the total transport distance. Leveraging this observation a simple, geometric explanation for the emergent ‘tree-like’ architecture of many natural systems is now achievable. Note that this ‘tree’ effect occurs when most of the flow volume exhibits diffusion, with a small percentage of interdigitated high flow velocity channels. One notable application of our novel method, path length analysis, is the automated creation of cooling channel networks for heat generating micro-chips. As a demonstration, this path length analysis method was used to develop a significantly more efficient channel configuration (by 14%) than the state of the art for conductive microchip cooling. An extensive array of finite element models confirms the performance of this novel configuration.

Global Positioning Systems, thermal imaging scopes, satellite phones, and other electronic devices are critical to the warfighter in Forward Operating Environments. Many are battery operated and require charging. We used a Systems Engineering approach to compare existing portable energy systems and to specifically design a portable solar energy system for use tailored for a deployed military/combat unit. We considered ease of setup/teardown, power delivered, weight, and many other factors that contribute to the level portability required. As deployed units are often in areas with little or no permanent sources of electricity, powering and/or charging electronic devices can be a challenge and diesel generators are the typical solution. Generators require fuel (approximately 1 gallon/hour for 10 kVA) which is extremely costly in both money and safety of soldiers tasked with transporting fuel. Understanding the factors that affect portability and knowing which ones are the most important is key to determining whether a particular energy generation system is an asset or liability. Currently, there is no simple rubric to characterize what portability is and how to compare two systems. We therefore created a rubric to aid our analysis of portability. With such a set of measurements and procedures, designs can be meaningfully compared and once designed, we used the new metrics to improve our overall design. Several conceptual designs were drafted and compared, using the metric, to current diesel generators used by the U.S. military in both Iraq and Afghanistan. We identified areas where diesel generators are superior and areas where the solar energy systems are superior. The remainder of this paper outlines our process and results.

Many factors must be addressed when designing infrastructure health monitoring systems. Structures in remote locations or with limited accessibility make the requirements for these systems unique and challenging. For locations where connection to the power grid is difficult or impossible, monitoring system life is severely limited by battery technology. Alternatively, an energy harvesting power supply can make the monitoring system independent of the grid while increasing capabilities and lifetime beyond what is possible with current battery technology. This paper discusses a design and development methodology for developing energy harvesting aspects of a health monitoring system. The system comprises a sensor module that monitors the health of the structure, an on-site processing module that analyzes the data, and a wireless communication module that transmits the data. The method is demonstrated by examples of energy harvesting systems for a bridge monitoring application, using solar, wind, and vibration energy harvesters to provide power to a wireless network, local data processors, and strain gauges. Theoretical feasibility of energy harvesting in these domains has been previously demonstrated. The examples described in this paper validate the feasibility previously calculated as well as illustrate shortcomings in the current technology that inhibit potential implementation. The examples also show areas where innovation is needed to continue to advance the technology of energy harvesting in this application on infrastructure.

Extensive VCSEL reliability enhancements have been carried out at Emcore in the past year with significant results. In this talk, we will present the failure mechanisms, the method and effectiveness of wafer and die screening, and the approaches to eliminate these failure mechanisms. Results of improved reliability will also be discussed.

Although the pedagogical advantages of active learning are apparent from the literature, the use of these techniques is not yet pervasive in the engineering curricula. This is due, in part, to the lack of a smooth implementation path. A major roadblock to implementation of active learning techniques is the lack of ready-to-use active learning products (ALPs) and procedures. To remedy this, over 25 active learning products have been created for engineering mechanics. In addition, a general and repeatable approach for developing the active learning products, the PHLIpS Method (Producing Hands-on Learning to InsPire Students) and associated assessment instruments were created for application across STEM programs. The workshop overviewed many of the activities and focused on providing participants with the tools needed to implement and evaluate active learning in their classrooms. A post workshop survey provided participants evaluation of the workshop and the PHLIpS Method. Overall the workshop feedback was very positive and avenues for improvement to the PHLIpS Method also resulted.

Many methods for design have been explored as the engineering community seeks to increase the efficiency, quality, and novelty of innovation. Some design methodologies are well equipped for use with any problem; others are best suited for specific domains or applications. Recent studies have developed two new independent methods for design. The first, WordTree Design-by-Analogy, uses a graphical structure of related words to help identify far-field analogies that have relevance to a given problem. The second method, Transformation Design, describes the mechanics and characteristics that drive the transformation of a reconfigurable mechanical system from one state to another. This paper presents a study of the effectiveness of these two methods in generating concepts for a specific problem statement requiring multiple sets of capabilities, i.e., tagging and tracking vehicles for military or civilian law enforcement purposes. Forty-one mechanical engineering students were assembled into groups and given specific guidelines to follow in generating concepts. A typical full-factorial experiment and ANOVA analysis was used to compare the effect of using the two design methods, as well as the interaction between them. Results from the design teams were evaluated quantitatively by the number concepts generated. Analysis of these results revealed that using the Transformation Design method increased the number of concepts developed by 25–30%. Use of the WordTree method was not judged to increase the number of concepts generated; however, the novelty and diversity of solutions were distinct for this method compared to Transformation Design or the control group.

A transforming product is a system that has different functionality when physically changed or reconfigured into a different state. This increased functionality allows diverse customer needs to be met in a single product. Transforming devices have become more prevalent in recent years, as customers desire both increased capabilities and reduced complexity to reduce waste in our society. When designing a multifunctional product that transforms from one state to another, it can be difficult to conceptualize a design that does not reduce effectiveness or provide a compromise in either state. Transformational Design Theory has been developed and shows basic principles and facilitators that enable transformation to occur within a product space. An illustrative example is a chair designed to flip over to be used as a table. Flip is one of the 19 facilitators that are found in transformation design. This is also an example of expose/cover, a transformation design principle. Certain principles and facilitators are more prevalent than others in different design domains (such as tools, storage, organisms etc.). If we know the states that exist within the transformer, concept opportunity diagrams can be used to determine the opportunities for transformation within each state. When the diagrams are paired with a constituent relationship chart specific to each domain, new design concepts may be facilitated. This technique creates a cognitive process for designers where they process a series of questions when creating the concept opportunity diagram. The diagram will help them understand the unanticipated additional design space of each state. The Constituent Relationship Chart is a tool that allows them to apply their knowledge of these states to the facilitator hierarchy so that prospective facilitators can directly contribute to originally unforeseen design concepts. This paper presents this twofold process known as the Transformer Diagram Matching Method and shows the results on a fully functioning prototype of an office supply transformer. Although the proposed process is detailed, it allows the designer to find a large number of quality concepts they would not have foreseen otherwise. Our original concept generation processes produced thirty eight ideas, but this process added another thirty two ideas to the design space. The paper indicates specifically how this method can be integrated in with the standard transformational design process as well as suggests strategies for implementation within other design techniques.

Transforming products, or more generally transformers, are devices that change state in order to facilitate new, or enhance an existing, functionality. Mechanical transformers relate to products that reconfigure and can be advantageous by providing multiple functions, while often conserving space. A basic example is a foldable chair that can be stowed when not in use, but provides ergonomic and structural seating when deployed. Utilizing transformation can also lead to novel designs that combine functions across domains, such as an amphibious vehicle that provides both terrestrial and aquatic transportation. In order to harness these assets of transformation, the Transformational Design Theory [1] was developed. This theory outlines a set of principles and facilitators that describe and embody transformation for the purpose of systematically assisting the design of transformers. To build on this theory, this paper analyzes a repository of popular transformer toys. Transformer toys are chosen for this study because of their richness in displaying a variety of kinematic aspects of transformation. Through this process, new definitions to describe transformation are garnered and a set of guidelines are developed to further aid designers. The empirical data set of transformer toys is rich in information and provides a basis for application to other fields, such as robotics and consumer products. These insights, in conjunction with the use of storyboarding, create a new method of designing transformers. This paper presents the method and concludes with a validation exercise in the creation of a new transformer toy.