Engineering Design Process Steps

"The value of a prototype is in the insight it imparts, not the code" Prototyping lets us fail fast and cheap, or get the data to make a concrete decision on direction. It helps answer the question, "What happens if we try this?". Most significantly, prototyping provides us with the guardrails to safely and productively fail. Prototyping is the right tool if you have an idea to validate, a clear path to get feedback on, or a proposal requiring further data. It provides crucial insights to move forward. By creating a rough version of a feature or system you've been considering, you gain the flexibility to either discard the idea or fully commit to it. It's a skill that assists product and engineering teams in making pivotal business decisions. Whether it's a website, mobile app, or landing page, no matter what product you're working on, it's always essential to verify your design decisions before shipping them to the end-users. Some development teams delay the validation stage until they have a solution that is almost complete. But that's an extremely risky strategy. As we all know, the later we come across the problem, the more costly it becomes to fix it. Luckily, no matter what point you are in the design process, it is still possible to build and test a concrete image of your concept—a prototype. Consider an architect tasked with designing a grand building. Before laying the first stone, the architect crafts a miniature scale model, allowing them to visualize the end result, understand the project's complexities, and present their ideas convincingly to others. However, this model is far from being the final product; it's a means to an end. This principle applies just as aptly in the world of software development. A software prototype—whether it's a low-fidelity wireframe, a high-fidelity interactive model, or a simplified mock-up of a more complex system—is much like the architect's scale model. It's a visual, often interactive, model of the software that provides developers, stakeholders, and users with an early glimpse into the software's workings, long before the final product is ready. The prototype isn't about the code per se; the code is merely a tool used to create it. Instead, it is about gathering valuable insights, comprehending user needs, identifying functional requirements, validating technical feasibility, and discovering potential stumbling blocks that might arise during full-scale development. The prototype's strength lies in its capacity to provide these insights without necessitating a significant investment of time or resources. I'm a big fan of using prototypes in our work at Google. Their value is often high. Wrapping up... The aim of prototyping is not the prototype itself or its immediate output but the knowledge that comes from it. I wrote more on this topic in https://lnkd.in/gEEGFwJp #softwareengineering #programming #ux #design

🏭 PCB Design Fundamentals Day 7: Design for Manufacturing The gap between a functioning prototype and a mass-producible product is where many engineers stumble. Three DFM principles that prevent manufacturing headaches: 1. Design to the middle of your manufacturer's capabilities, not the edge (if they have 15% trace width variance, design for wider than desired or say, the average thickness of the dielectric for impedance, not the thinnest dielectric) 2. Standardize via sizes even when smaller vias are possible (why? Fewer drilling variations, easier manufacturing, lower costs to you) 3. Account for solder mask tolerances in pad design (you can set these to zero in many cases. the manufacturing team can modify it) When you design for manufacturing before you start that PCB, you will get fewer surprises when you send that board in. What manufacturing constraint has caused you the most trouble? #DesignForManufacturing #PCBProduction #ManufacturingYield Some DFX resources from the manufacturers: Sierra Circuits DFM Guide https://lnkd.in/gCexnhDM Advanced PCB (Advanced Circuits) https://lnkd.in/gjHhbBT6 PCB Way (issues one may not find in a guide): https://lnkd.in/gUB9jqqR

Pressured to converge on a design direction quickly? ⏱ Timelines are tight, stakeholders are eager and the pressure to “just pick a direction” is real. But rushing without validation often leads to misalignment, wasted effort, and features that don’t solve the real problem. You don’t need a huge budget, formal lab, or dedicated researchers to validate your design decisions. Even small, strategic actions can give you the confidence to move forward. Depending on your team and resources, here's a few options: ※ Quick feedback sessions – bring in fresh eyes and run internal stress-tests ※ Concept testing with users – low-fi prototypes, casual coffee chats, or short calls ※ Assumption mapping workshops – surface risks before they become real problems ※ A/B testing – when hypotheses are measurable and ready for data-driven decisions The goal of early validation isn’t perfection—it’s confidence. Enough signal to move forward without second-guessing, redoing, or wasting energy on the wrong direction. 💡 How do you validate early design directions in your team? What small techniques give you the clearest signal? Share your approach below 👇

Good engineering is wasted if you build the wrong product. The other day, I meet a founder. He says “Oh, you’re a CTO?” He hands me his phone. “Can you look at my app? I'm not sure my engineering team did a good job.“ I say “it’s hard to be sure just by clicking around, but the layout seems fine, the performance is snappy. What’s wrong with it?” “Well, people aren’t using it enough” Ah, the plot thickens. As it happens, the engineering team is doing fine. But they’re contractors. They’re given Figma mocks and do a pixel-perfect implementation. But how do those mocks get created? They’re just following an arbitrary roadmap based on the founder’s intuition. Having strong intuition for what your users want is helpful, but it never happens in a vacuum. Your job as a founder is to talk to your users. A lot. When you all you have is a wireframe, show your users and look for validation that it meets a real need they’d be willing to pay for. When you have a higher-fidelity prototype, do it again. Summarize, and share these summaries with your engineers. Everyone who touches execution should be reading them. Once you’ve launched, mine insights from your monitoring tools. Do new features improve these metrics? If early testers aren’t engaging, ask why. Always assume you’re missing some key insight about user needs and be relentless in squeezing this insight from your users. Until you have product-market fit, the most valuable thing your users have for you isn’t their money, its their honest feedback. Getting this feedback isn’t easy, but it’s the shortest path to iterating on your product effectively. If you’re not doing this, you’re likely wasting precious time and engineering resources. 10 hours of talking to users saves you 100s (1000s?) of hours building the wrong thing.

🔋 How to Size Solar Panels Using PVsyst — A Beginner’s Guide Designing a solar system without proper panel sizing is like building a house without a foundation. ⚡ Luckily, PVsyst makes this process structured and accurate. Here’s a simple breakdown of how to size solar panels using PVsyst 👇 🌞 1. Define Project Site & Irradiation Choose your location or import a custom meteo file. PVsyst auto-generates solar radiation data — this defines how much sunlight is available. 🧱 2. Input System Constraints Decide whether it's a grid-tied, off-grid, or hybrid system. Set desired system size (e.g., 100 kW), or let PVsyst calculate it based on energy needs. 🔋 3. Choose Panel Specs Select a PV module from the database or enter custom specs (Wattage, Voc, Isc, etc.) Define the number of panels in series & parallel to match your inverter’s input range. ⚙️ 4. Optimize Tilt & Azimuth Set tilt based on latitude or optimize using simulation. Define azimuth (angle from south) to improve annual yield. 🔌 5. Match with Inverter Choose an inverter from the library. Ensure your string configuration is compatible with its voltage & power range. 📈 6. Run Simulation & Analyze Losses PVsyst provides a detailed loss diagram: mismatch, shading, temperature, wiring losses, etc. You get the final expected energy output (kWh/year). 📉 Result? A realistic system sizing report that helps: ✅ Clients understand expected generation ✅ Designers avoid oversizing or inverter mismatch ✅ Installers reduce surprises on-site --- 💬 Want a complete PVsyst sizing report template or help with a simulation? Drop a comment or DM me — I’d be glad to share! 📞 Let’s connect! 🔹 WhatsApp: +923073558882 🔹 Email: imamsolardesign31525@gmail.com 🔹 Instagram: @solar_design_engineer #PVsyst #SolarDesign #SolarEngineering #FreelancingEngineers #RenewableEnergy #SolarPanels #SystemSizing #ElectricalEngineering #CleanEnergy #FreelancerTips #PakistanSolar

Concept testing unlocks better design ideas. When I work with teams, I often find they are eager to get feedback on a full user flow before they even know what parts of it people find interesting or easy to understand. In most cases, concept testing is more helpful at this stage. It forces teams to think more creatively by figuring out how different parts of a design work together. Once you’ve found what matters in the design, task analysis is great for fine-tuning the details. Think of it this way: concept testing is intentionally messy. It’s meant for exploring ideas. Task analysis is structured. It’s used to test and validate a direction. They both matter but are useful at different points in the process. We use concept testing to test many ideas or directions with an audience to see what works. Most of the time, with multivariate testing, there’s no need to worry about perfect order or flow. Continuous testing reveals patterns. → start with a basic idea or concept → get broad feedback on different versions or directions → try out different combinations or steps → use it to open up possibilities → learn what works and shape your direction We use task analysis to check whether a specific flow or task makes sense to people. → start with a clear task → have users go through it step by step → see if they can complete it easily → use it to confirm the design works as expected Concept testing helps you explore what’s possible.  Task analysis helps you make sure it works. Use both, but know when to use which! #productdesign #productdiscovery #userresearch #uxresearch

The garment sampling process is a step-by-step procedure used in the fashion and apparel industry to ensure that clothing items are accurately designed, sized, approved, and ready for mass production. Here's a breakdown of each stage: 🔹 1. Proto Sample (Design Checking) Purpose: The first sample made after receiving the initial design or tech pack. Focus: Design accuracy, styling, and construction. Goal: To visualize and evaluate the concept. 🔹 2. Fit Sample (Measurement & Fit Check) Purpose: To check the garment’s fitting on a mannequin or model. Focus: Fit, measurement accuracy, and comfort. Goal: Ensure proper proportions and silhouette. 🔹 3. Size Set Sample (Multiple Size Verification) Purpose: Samples created in all sizes (S, M, L, etc.). Focus: Fit and measurement consistency across sizes. Goal: Validate that grading rules are correctly applied. 🔹 4. Photo Sample (For Catalog / Marketing) Purpose: Used for promotional materials like catalogs or websites. Focus: Aesthetics and presentation. Goal: Showcase the final design for marketing. 🔹 5. Salesman Sample (Promotion to Clients) Purpose: Sent to buyers and clients before final orders. Focus: Quality, fit, and appearance. Goal: Secure purchase orders. 🔹 6. Pre-Production Sample (Final Approval) Purpose: The final version before mass production. Focus: All elements—fabric, color, trims, measurements. Goal: Official approval for production to begin. 🔹 7. Counter Sample (Final Reference Copy) Purpose: A duplicate of the approved pre-production sample. Focus: Used by the factory as the production benchmark. Goal: Maintain quality consistency during manufacturing. Each stage serves a critical purpose to minimize errors, optimize fit, and ensure production readiness, ultimately saving time, money, and resources. #garmentsindustry #garments #TextileKnowledge #GarmentsBangladesh #samplingtechniques #textileguide #TextileEngineering #foryoupageシ

Designing & Selecting the AC/LV Side of a Solar System ⚡ Proper selection of switchgear, cables, earthing, and protection on the AC/LV side of a solar system ensures efficiency, safety, and compliance with electrical standards. Here’s a breakdown of key considerations: 🔹 1. Switchgear Selection (AC Panels & Breakers) ✅ Voltage Rating: Matches system LV output (typically 400V AC 3-phase or 230V single-phase). ✅ Current Rating: 125%-150% of inverter AC output. ✅ Breaking Capacity: Withstands maximum fault current (e.g., 10kA–50kA). ✅ Types of Breakers: 🔸 MCBs – Small loads & distribution panels. 🔸 MCCBs – Main AC distribution & large inverters. 🔸 AC Isolators – Safe inverter disconnection. 🔸 Contactors & Relays – Automation & remote shutdown. 🔹 2. AC Cable Sizing & Selection ✅ Voltage Rating: 600/1000V LV or 1.8/3kV near transformers. ✅ Current Carrying Capacity: Choose based on ampacity & heat dissipation. ✅ Derating Factors: Consider temperature, grouping & burial method. ✅ Voltage Drop: Should be ≤1.5% from inverter to point of connection. ✅ Cable Type: 🔸 XLPE-insulated copper/aluminum cables for heat resistance. 🔸 Armored (SWA/AWA) cables for underground use. 🔸 Flexible cables for panel connections. 📌 Example: For a 100kW inverter (3-phase, 400V, 145A), 50mm² copper cable is typically required (based on ampacity & voltage drop limits). 🔹 3. Earthing & Grounding System ✅ System Earthing: TN-S, TN-C-S, TT, or IT (as per grid codes). ✅ Equipment Earthing: 🔸 Inverter frames, mounting structures & AC panels (≥16mm² Cu or ≥25mm² Al). ✅ Surge Protection Earthing: Separate earth pits, ≤5Ω resistance recommended. ✅ Earthing Conductors: ≥25mm² Cu for main earth connections. 🔹 4. Protection System (SPDs, RCDs & Overcurrent Protection) ✅ Surge Protection Devices (SPDs): 🔸 Type 1 – Lightning protection (if direct strikes possible). 🔸 Type 2 – General surge protection (for inverters & switchgear). 🔸 Type 3 – Local protection for sensitive electronics. ✅ Residual Current Devices (RCDs): 🔸 30mA – Personal safety. 🔸 100mA–300mA – Fire protection. ✅ Overcurrent Protection: MCCBs/MCBs sized at 1.25x inverter AC current. ✅ Anti-islanding Protection: Ensures grid safety by disconnecting during outages. 🔹 5. Compliance & Standards 🔸 IEC 60364 – Electrical Installations (LV systems). 🔸 IEC 60947 – Switchgear & controlgear. 🔸 IEC 61643 – Surge protection devices. 🔸 IEC 62477 – Safety of power electronics. 🔸 Local utility/grid codes for interconnection. 💡 Conclusion Selecting the right AC side components ensures: ✅ Safe & efficient power distribution ✅ Compliance with electrical standards ✅ Reliable protection against faults & surges #SolarEnergy #ElectricalDesign #RenewableEnergy #ACSide #SolarEngineering #SustainableTech

"CTRL + P" works for documents, but PCBs? Not so much. Here’s the reality! Printing PCBs is not as simple as hitting *CTRL + P*. You need to be careful when exporting your Gerber files. Even the best design won't work if your fabricator can't understand it, leading to non-functional PCBs................ Here's a checklist to help you get it right: 1. Layer Configuration: ↳ Check the layer stack-up matches your design. ↳ Include all necessary layers (e.g., copper, solder mask, silkscreen). 2. Drill Files: ↳ Include all drill holes and pad sizes. ↳ Ensure the format matches the fabricator's requirements. 3. Board Outline: ↳ Verify dimensions are accurate. ↳ Clearly define the board's edges & cutouts. 4. Component Placement: ↳ Ensure adequate spacing for soldering. ↳ Place components correctly without overlaps. 5. Design Rules Check (DRC): ↳ Run a DRC to catch spacing or clearance issues. ↳ Adjust violations according to the fabricator’s specs. 6. Netlist Verification: ↳ Ensure no unintentional shorts or opens. ↳ Cross-check the netlist with your schematic. 7. Silkscreen Clarity: ↳ Make text and labels readable and away from pads. ↳ Avoid placing silkscreen over vias or copper areas. 8. File Naming and Format: ↳ Use clear file naming conventions. ↳ Confirm the Gerber format is compatible with the fabricator. 9. Panelization (if needed): ↳ Ensure panelization follows the fabricator’s guidelines. ↳ Include fiducials and tooling holes for alignment. 10. Final Review: ↳ Review everything or ask a colleague to check. ↳ Include necessary documentation like assembly drawings and BOM. Being careful with your Gerber files is crucial because even a small mistake can lead to non-functional PCBs, wasting time and resources. P.S. Did I miss something? Let me know in the comments below 👇 P.P.S. If you find this useful, don't keep it to yourself, repost! ♻️ --- 📌 If you're interested in building your own product with me, let's hop on a quick call and get a free 1-on-1 session! (𝗹𝗶𝗻𝗸 𝗶𝗻 𝗯𝗶𝗼) #pcbdesign #hardware #engineering #productdevelopment #electronics #embeddedengineering