This course provides students with an opportunity to conceive, design and implement a product, using rapid prototyping methods and computer-aid tools. The first of two phases challenges each student team to meet a set of design requirements and constraints for a structural component. A course of iteration, fabrication, and validation completes this manual design cycle. During the second phase, each team conducts design optimization using structural analysis software, with their phase one prototype as a baseline.

Acknowledgements

This course is made possible thanks to a grant by the alumni sponsored Teaching and Education Enhancement Program (Class of '51 Fund for Excellence in Education, Class of '55 Fund for Excellence in Teaching, Class of '72 Fund for Educational Innovation). The instructors gratefully acknowledge the financial support.

The course was approved by the Undergraduate Committee of the MIT Department of Aeronautics and Astronautics in 2003. The instructors thank Prof. Manuel Martinez-Sanchez and the committee members for their support and suggestions.

Special software is required to use some of the files in this course: .xls, .sldprt,

Syllabus

Description

This course develops a holistic view of and initial competency in engineering design by conceiving, designing, manufacturing and testing a system component such as a complex structural part. Activities include hand sketching, CAD modeling, CAE analysis, CAM programming and operation of CNC machining equipment. Requirements compliance is verified in the laboratory via structural testing. Initial designs are improved by means of multiobjective design optimization. The focus is on the design process itself as well as the complementary roles of human creativity and computational methods and tools. Designs are executed by pairs of students who enter their products in a design competition. The pedagogy is based on active learning and a balance of lectures and hands-on activities. Enrollment may be limited.

Prerequisites

16.010, 16.020 or 2.001, 2.002 or permission of instructor
U (IAP)
Units: 3-3-0
Letter Grading (A-F)

Rationale for Offering this Subject

A recent survey of undergraduate students in the Department of Aeronautics and Astronautics (in conjunction with the new Department Head Search in 2003) has shown that there is a desire for training in modern design methods using state-of-the-art CAD/CAE/CAM technology and design optimization. Individual students have suggested the addition of a short and intense course in rapid prototyping, combined with design optimization. The intent of this course is to respond to this perceived gap, while exploiting synergies with other engineering departments that have articulated similar needs.

2004 Course Abstract

Readings

The main text for the class is presented below. Other readings, notes, and articles were distributed as necessary in class.

 Katz, Joseph. Race Car Aerodynamics: Designing for Speed (Engineering and Performance). Cambridge, MA: Bentley Publishers, 1995. ISBN: 0837601428.