This paper contributes with insights regarding design expertise and prototyping. Seven high performers – Outstanding Designers – were interviewed to learn about their prototyping activities. The Outstanding Designers emphasised prototyping for reflection, gaining certainty, and cooperating with clients. They expressed a strong attachment regarding the use of prototyping that results in specific routines. We call this behaviour the Outstanding Designers’ bonding with prototyping. The main insights were synthesised into a model outlining the relation between design expertise and prototyping.

In the field of 3D model reconstruction, manifold methods have been developed that derive CAD models from 3D scan data. Opposed to classical CAD modelling, where surface and solid modelling exist, a further diversification of modelling techniques is observed, caused by different methods to build up the geometry. This research introduces a new classification, the so-called Level of Complexities. It can be applied to the complete Reverse Engineering process chain and lays the foundation for further research on how to match requirements arising from all process steps and downstream applications.

The use of design methods across multiple design phases of the product development process often leads to inconsistency, the loss of transparency, and the rejection of design methods by practitioners. The authors of this work intend to develop a central modelling approach that supports consistency, based on the integrated function modelling (IFM) framework. Therefore, various design methods from the literature were examined for their techniques and content to identify indicators for supporting consistency. The results led to an enhancement of the IFM framework.

This paper examines upgradability through modular product design, aiming to extend lifecycles and promote cross-generational use. It builds up on a preceding work, a systematic literature- review identifying four fields of action in future-robust product design. The paper itself contains an in-depth interview study with 17 experts from industry and research to validate and expand the literature-based fields of action. The results provide insights into the application and employment of future-robust product design, with a focus on adaptable product architectures.

With recent advancements in Virtual reality (VR), 3D design in VR has gained significant interest from both academia and industries. However, the development of these VR CAD tools is either skewed towards the creative industry or simply mimicking conventional CAD. This paper presents three different tools, analyzes them, and compares their capabilities over various performance parameters. The paper finally suggests where these tools can be used in the design process and some critical pathways for developing VR-based CAD modeling software for practical use in the engineering design industry.

The presented study investigates differences in engineering designers' CAD performance when modelling from two types of projections in technical drawings – isometric and orthographic. The results revealed significant differences in the percentage of correctly replicated components' size and shape, indicating better CAD outcomes when generating CAD models from the orthographic projection. In addition, a comparison of duration, as well as the number and type of sketch entities, sketch relations, and CAD features, showed that CAD modelling processes were similar in both conditions.

Software implementations of traditional engineering design methods can potentially enrich the original methods. A study was conducted to better understand how concept generation can be facilitated using software. Participants of the study were asked to generate concepts using either specialized software, or by using traditional means, for applying function-means modeling and morphological matrices. A concept concretization metric was used to evaluate the results, which indicated that there are both positive and negative aspects of performing concept generation using specialized software.

Selecting right positions for composite-integrated sensors for monitoring cure during manufacturing and loads during product use presents challenges for engineering design. Since an optimal sensor placement (OSP) methodology for both phases is not emphasised enough in literature, a new methodology is proposed. This methodology is based on a Genetic Algorithm and strain gauges, temperature sensors and interdigitated electrode sensors for cure monitoring and physics-informed neural network-based load detection. Additionally, it includes sensor node positions optimization in a sensor network.

Generative design is now a core capability of today's CAD systems enabling broader exploration of the design space. This paper presents a desktop review of 15 tools with the aim of characterising where the tools are used in the design process and to what extent they can be considered creative.The results showed that, despite their increasing capabilities, GD tools are unable to exhibit all phases of creativity and cannot be applied in all stages of the design process. This highlights the criticality of the human in design providing opportunities for GD to augment designer creativity.

Sustainability is influencing the automotive industry. Car manufacturers are increasingly prioritizing sustainable materials. The production of these still pose environmental challenges. This paper addresses the trends related to sustainable car interiors. It emphasizes the importance of understanding how customers perceive these new materials. Seven in-depth interviews were conducted, followed by a survey with 106 participants to obtain generalized insights. The results will reduce the uncertainty regarding customer expectations for sustainable car interiors.

The spare parts play a vital role in sustaining the operation and longevity of products and systems, but their unavailability can lead to prolonged downtime or expensive replacements. The integration of 3D scanning and Additive Manufacturing (AM) presents a promising path for spare part production. However, to utilise the full potential of AM, sometimes, redesign of the original part is needed. This paper investigates and proposes a new approach that integrates reverse engineering and redesign of an original part based on functional analysis to support the manufacturing of AM spare parts.

Yacht design process currently faces challenges as slow data sharing, lack of flexibility in modelling and inefficient optimisation of shapes. This paper assesses the potential of an integrated approach over the traditional one, using a hypothetical industry scenario. The key aspects of data sharing/project management, modelling system, and shape optimization are compared, and new collaborative tools and technologies are introduced. The research reveals significant benefits of the integrated approach over the traditional one highlighting its potential to foster innovation within the industry.

The research paper delves into the importance of point cloud data obtained from 3D scanning technology ensuring quality control in industrial settings. It presents a new heuristic approach that utilizes the wavelet algorithm and other techniques to detect and characterize induced forming defects accurately. The proposed approach offers more flexibility, ease of use, and better results based on descriptive and prescriptive analyses from DRM. The results demonstrate that the wavelet algorithm was successful in identifying and characterizing forming defects in point cloud data.

In recent years, the importance of design has been pointed out as a source of competitive advantage. However, creating a great design also increases the risk of copy products being created. In this study, we used an approach based on visual information and conducted an international comparative judgment survey of elements considered to be similar within products.

A volatile environment and an increasing number of products along with a growing range of functions pose a challenge for companies when it comes to further development. Existing methods are no longer sufficient to cope with these challenges. In order to develop new methods, the process and challenges in the advancement of product portfolios must be understood. In this paper we conduct an interview study with ten experts to gain a better understanding of the advancement of product portfolios. Triggers, changes and actions are examined and goals and requirements for new methods are derived.

This paper conducts a systematic literature review about the management of rule-based product-portfolios with high variance. This type of portfolio is particularly distinctive in the chosen use case of the German automotive industry since it satisfies the requirements of mass customization and modularization. However, the research field of variant- and complexity management is manifold and multidimensional. This paper systematically searches the databases Scopus and Web of Science using the PRISMA method and briefly summarizes the main contributions and comparing them by elaborated topics.

This study presents a search method for a solution space that aligns with a designer's design intent. The proposed method uses multiobjective optimization to determine the size of the narrowed solution space and the weakness of the constraint relationships between the design variables. The suitability of the proposed method is tested by applying it to the design problem of an electric motor for an EV, aiming to provide designers with solution spaces that offer a high degree of freedom in the later design stages and that have weaker constraint relationships among the design variables.

Immersive reality (XR) technologies, particularly Mixed Reality (MR), offer promising opportunities for enhancing design prototyping. While recent studies often focus on Virtual Reality this work explores the application of MR, where focus lies on interlinking both the physical and digital to maximise benefit. Following a review of XR in design, a descriptive framework is presented to characterise MR prototyping. Two case studies are then presented to highlight the value of bridging the physical and digitalf worlds, before directions for further research in MR-based prototyping are outlined.

Lab-on-a-Chip (LOC) products for point-of-care diagnostics have gained significant attention. However, there is a lack of systematic approaches for LOC product development. To address this, we introduce an Attribute Dependency Graph exemplary for a magnetophoretic LOC system for pathogen detection. This model organizes dependencies between the design variables and crucial quantities of interest, such as detectability, cost per test, and test duration. The obtained model helps to manage design complexity and can be adapted to other LOC approaches.

The growth in e-commerce has led to increased demand for logistics services. This puts a pressure on third-party logistics (3PL) providers who struggle with increasing operating costs and heightened competition. These providers could potentially exploit the advantages of modularisation, but few studies address the design of modular logistics services. This study explores modular design of logistics services and proposes a model to describe logistics service architecture based on product architecture. A case study shows that warehousing services can be described in three domains.