As digitization progresses, the integration of information and communication technologies in technical systems is constantly increasing. Fascinating value potentials are emerging (e.g. autonomous driving), but also challenges in the system development. The constantly increasing product complexity and degree of networking require a systemic development, which is fulfilled by established approaches of Model-Based Systems Engineering (MBSE). To ensure the reliability of tomorrow's systems, an integrative and early consideration of security and safety is additionally required. In order to show the possibility and consequences of failures and attacks, the paper develops a modeling language that links established and partly isolated security and safety approaches within a consistent metamodel. The developer is enabled to synthesize system architectures transparently on an interdisciplinary level and to analyze attack and failure propagation integratively. The approach uncovers synergetic and especially contrasting goals and effects of architectural designs in terms of safety and security in order to make adequate architectural decisions based on trade-off analyses.

Additive manufacturing (AM) is a versatile technology that could add flexibility in manufacturing processes, whether implemented alone or along other technologies. This technology enables on-demand production and decentralized production networks, as production facilities can be located around the world to manufacture products closer to the final consumer (decentralized manufacturing). However, the wide adoption of additive manufacturing technologies is hindered by the lack of experience on its implementation, the lack of repeatability among different manufacturers and a lack of integrated production systems. The later, hinders the traceability and quality assurance of printed components and limits the understanding and data generation of the AM processes and parameters. In this article, a design strategy is proposed to integrate the different phases of the development process into a model-based design platform for decentralized manufacturing. This platform is aimed at facilitating data traceability and product repeatability among different AM machines. The strategy is illustrated with a case study where a car steering knuckle is manufactured in three different facilities in Sweden and Italy.

Robust Design offers a coherent and widely appreciated approach for the parametric exploration of the design space by means of simulation or experimentation, which is well-established in the quality-by design domain. From the perspective of design research, however, this only addresses a relatively narrow part of the design process and is not fully integrated with other design decisions such as concept exploration, the suitable configuration of system elements, or the design of interfaces. Particularly in light of the growing importance of developing technologically advanced and “smart” systems, it seems that a new methodical perspective on Robust Design is needed. Against this background, this paper consolidates knowledge and insights from different research fields and industry sectors. On this basis, new angles to the discussion on product robustness in different domains are explored in order to suggests directions for action and new research areas, both with respect to a methodical RD approach as well as the question of systematic research procedures.

Research funded projects are often concerned with the development of proof-of-concept products. Consequently, activities related to verification and validation testing (VVT) are often not considered in depth, even though various design iterations are carried out to refine an idea. Furthermore, the introduction of additive manufacturing (AM) has facilitated, in particular, the development of bespoke medical products. End bespoke products, which will be used by relevant stakeholders (e.g. patients and clinicians) are fabricated with the same manufacturing technologies used during prototyping. As a result, the detailed design stage of products fabricated by AM is much shorter. Therefore, to improve the market-readiness of bespoke medical devices, testing must be integrated within the development from an early stage, allowing better planning of resources. To address these issues, in this paper, a comprehensive VVT framework is proposed for research projects, which lack a VVT infrastructure. The framework builds up on previous studies and methods utilised in industry to enable project key experts to capture risks as early as the concept design stage.

Over the last years, academic literature has made significant progress on the development of key concepts, identifying circular product typologies, developing assessment methods, and exploring the synergies with manufacturing trends such as digitalisation or environmental management. Nevertheless, less attention has been paid on describing process model changes necessary for the implementation of circular product development. For this reason, this paper presents the circular Sustainable Product Development (cSPD) morphological field, aimed at providing implementation guidance to business and industry. It describes possible reconfigurations of the Sustainable Product Development (SPD) process model to further integrate circularity R-strategies, design scopes, design guidelines, inter- and intra-organisational actors and criteria for evaluation. With this framework, we intend to identify the most defining parameters in the process model and assign them a discrete number of categorical values so that different combinations explain the generation of prevalent circular product typologies in the manufacturing of durable goods.

The current ways of coping with uncertainty such as changes during product design or use have been through methods such as easy restructuring (e.g., modularity with buffer in interface definition), by overdesign and so on. The present investments on maintaining products in the economy for “as long as possible” is challenging these strategies from a cost and environmental perspective. Moreover, these strategies often lead to highly overdesigned products. An alternative strategy is to introduce features in a design, called “resilient objects”, which are able to absorb such uncertainties without wasteful overdesign of other parts. By applying a ‘text-mining’ approach on patents, this paper has identified 5,552 candidates for such resilient objects that can be recombined and inserted in regions of the product that are likely to be most affected by current and future uncertainties. The application of resilient objects is demonstrated on a case study (a cooling system for battery electric vehicles). The case study highlights the ability of these objects to 1) significantly increase protection against uncertainties without the need for restructuring, 2 ) reduce the risk for overdesign and 3) dampen effects of change propagation.

Conventional failure analysis ignores a growing challenge in the responsible implementation of novel technologies into engineered systems - unintended consequences, which impact the engineered system itself and other systems including social and environmental systems. In this paper, a theory for unintended consequences is developed. The paper proposes a new definition of unintended consequences as behaviors that are not intentionally designed-into an engineered system yet occur even when a system is operating nominally, that is, not in a failure state as conventionally understood. It is argued that the primary cause for this difference is the bounded rationality of human designers. The formation of unintended consequences is modeled with system dynamics, using a specific real-world example, and bifurcation analysis. The paper develops propositions to guide research in the development of new design methods that could mitigate or control the occurrence and impact of unintended consequences. The end goal of the research is to create a new class of failure analysis tools to manage unintended consequences responsibly to facilitate engineering design for a more sustainable future.

Structuring the early design phase of automotive systems is an important part of efficient and successful development processes. Today, safety considerations (e.g., the safety life cycle of ISO 26262) significantly affect the course of development. Preliminary designs are expressed in functional system architectures, which are required to form safety concepts. Thus, mapping tasks and work products to a reference process during early design stages is an important part of structuring the system development. This contribution describes the systematic creation and notation of the functional safety concept within the concept phase of development of an unmanned protective vehicle within the research project aFAS. Different stages of preliminary design and dependencies between them are displayed by the work products created and used. The full set of functional safety requirements and an excerpt of the safety argument structure of the SAE level 4 application are presented.

Although well researched and praised in academic publications, function modelling (FM) does not have gained much traction in industrial application. To investigate into possible reasons for this, this publication researches literature of nine different projects where enhanced function-means modelling has been applied. The projects are analysed for their purpose of FM-use, applied benefits and discovered challenges of the FM approach. From this, the main challenges for FM application are the abstraction level of the modelling language as well as the lack of an interface to CAD modelling.

In industry, there is at once a strong need for innovation and a need to preserve the existing system of production. Thus, although the literature insists on the necessity of the current change toward Industry 4.0, how to implement it remains problematic because the preservation of the factory is at stake. Moreover, the question of the evolution of the system depends on its innovative capability, but it is difficult to understand how a new rule can be designed and implemented in a factory. This tension between preservation and innovation is often explained in the literature as a process of creative destruction. Looking at the problem from another perspective, this article models the factory as a site of creative heritage, enabling creation within tradition, i.e., creating new rules while preserving the system of rules. Two case studies are presented to illustrate the model. The paper shows that design in the factory relies on the ability to validate solutions. To do so, the design process can explore and give new meaning to the existing rules. The role of innovation management is to choose the degree of revision of the rules and to make it possible.

Aircraft cabin monuments must be optimized in terms of lightweight design, cost structure and variance. Model-based approaches support the aircraft data and help to modify them consistently during further development. In this paper, a holistic methodological approach for product families of aircraft cabin development is shown, which integrates lightweight and cost-efficient aspects, in addition to the variance focus. For this purpose, the development of cost-efficient and ligthweight optimized cabin modules is supported in a model-based way.

Intercultural interactions encourage social inclusion and diversity, but they are often avoided due to prejudices. Intercultural Meaningful Social Interactions (IMSI) can overcome such prejudices; still, the literature lacks guidelines on how to promote them by Design. In this study, we propose eight design strategies to facilitate these interactions, which were originated by bridging four theories for prejudice reduction and exemplar IMSI experiences of 15 intercultural participants. This paper presents the strategies and discusses their use to inspire new design concepts for promoting IMSI.

It is estimated that about half of all innovations, such as innovations in mechatronic product-service systems (PSS), fail to deliver the expected benefits to the adopting organization. Different studies point out that one of the main reasons for this is an ineffective implementation process.

In this paper, we argue that, apart from several organizational challenges, insufficient integration of technical and social aspects is one of the reasons for ineffective innovation implementation in the environment of mechatronic PSS.

In order to remedy this weakness, this paper builds on the work of interdisciplinary research collaboration. Experts from technical, socio-technical, and management fields integrate their work within a conceptual innovation implementation management system (IIMS). This IIMS is capable of capturing various methods and models that foster the socio-technical integration in mechatronic PSS. The approach is assessed in a lab-scale demonstration case that is representative of industrial environments.

The presented approach supports an effective innovation implementation process, while the IIMS facilitates individual alignments for future practitioners.

The requirements space is increasing due to non-functional areas such as security, resilience and sustainability gaining in importance. This creates a complex and dynamic space which makes it hard for engineers to take good data driven design decisions. Increasing the quality of design decisions allows to better set up development projects and develop more successful products and services. The design can most heavily be influenced in the early design phases, where design flexibility is high and resource commitment is low. Unfortunately, the system knowledge is also low in early phases. The Engineering Graph is a concept that connects data from different internal and external sources. It allows to connect product data stored in Product Lifecycle Management systems with system models and also add external sources from the Wikimedia Knowledge Graph, World Health Organization and World Bank. This interconnected data allows the support of engineers in managing the complex and dynamic requirement space and provide high system knowledge in the early design phases to support design decisions.

Product-service systems (PSS) are being increasingly employed as opportunities to keep innovating. The design of PSS value propositions should focus on the value visualization for stakeholders. However, the PSS representations are still oriented to the customer’ perspective and focus on a process or technological role. This study aims to represent the PSS value proposition in a structured-diagram adapted from the journey map method in combination with the use of the elements of value. A case research was conducted with a high-tech agricultural start-up for representing its value proposition by following a process founded in the practices of journey mapping. Qualitative data analysis was employed to associate the elements of value with the solution, and to verify the consistency of the results. The representation enables the visualization of the stakeholders’ perception regarding the content of the solution as well as the potential value that may be related to it. The experience-centric perspective derived from the journey map associated with the value-related information provides a richer view of the PSS value proposition, which can lead to reflections regarding the solution.

Design research as a field has been studied from diverse perspectives starting from product inception to their disposal. The product of these studies includes knowledge, tools, methods, processes, frameworks, approaches, and theories. The contexts of these studies are innumerable. The unit of these studies varies from individuals to organizations, using a variety of theoretical tools and methods that have fragmented the field, making it difficult to understand the map of this corpus of knowledge across this diversity.

In this paper, we propose a model-based approach that on the one hand, does not delve into the details of the design object itself, but on the other hand, unifies the description of design problem at another abstraction level. The use of this abstract framework allows for describing and comparing underlying models of published design studies using the same language to place them in the right context in which design takes place and to enable to inter-relate them, to understand the wholes and the parts of design studies.

Patterns of successful studies could be generated and used by researchers to improve the design of new studies, understand the outcome of existing studies, and plan follow-up studies.

This research focuses on evaluating a user interface (UI) for an autonomous vehicle (AV) with the goal to determine the most suitable layout for persons with visual acuity loss. The testing procedure includes a Wizard of Oz AV for simulating an automated ride. Several participants are included in the study and the visual impairments are simulated by specially designed glasses. The conclusions help to determine the optimal graphic design of the UI that can be independently used by persons with blurred vision. The results can be applied to improve the inclusiveness and ergonomics of vehicle UIs.

This paper presents the re-design approach of an urban motorcycle helmet to prevent users bypassing the strap fastening system. Related studies show that although a full-face helmet provides the maximum protection to a rider, in practice, full-face helmeted riders in urban traffic tend to improperly fasten it. On that notion, the design goal was to conceive a helmet that combines the advantages of different helmet types while responding to urban driving needs. During design ideation possible solutions were examined focusing on different ways of accessing and fixating the helmet on a rider’s head, without using a strap fastening system. Preliminary concept development produced three design concepts, that were evaluated using two sets of prototypes: (a) the 3D printing method under a 1:2 scale was used to detect any design faults, while the 3D modeled concepts were evaluated in four different crash impacts regarding total deformation and von-Mises stress, and (b) 1:1 models of the three concepts were used by experienced riders to assess possible usability issues during helmet placement/removal. Results of the two-phase evaluation of the three concepts and design issues for further development of them are discussed.

Several researchers have reported on the effectiveness of knowledge-based inventive stimuli, known in the Theory of Inventive Problem Solving (TRIZ), in enhancing engineering creativity, but few authors have focused on the comparative analysis of structured ideation in engineering design in terms of quantitative and qualitative outcomes. Previous studies have mainly concentrated on the investigation of exemplary selected single stimuli rather than on a critical assessment of the relationship between the structured application of inventive stimuli and their contribution to engineering design. The paper describes a method for the automated formulation of elementary creative stimuli for product or process design at different levels of abstraction and in different engineering domains. The experimental study evaluates the impact of structured automated idea generation on inventive thinking in engineering design and compares it with previous experimental studies in educational and industrial settings. The outlook highlights the benefits of using automated ideation in the context of AI-assisted invention and innovation.

This paper presents a framework to develop the automated design of fixtures using the combination of design automation (DA), multidisciplinary optimization and robotic simulation. MDO necessitates the use of concurrent and parametric designs which are created by DA and knowledge-based engineering tools. This approach is designed to decrease the time and cost of the fixture design process by increasing the degree of automation. AutoFix provides methods and tools for automatically optimizing resource-intensive fixture design utilizing digital tools from different disciplines.