Points on the Design Process

On a recent business trip to China I was asked to talk to the top design engineers at Himin Solar about my design methods. It was suggested that I write down the main points. This is my advice to anyone who would like to follow my individual approach to design. Of course, nobody has to follow all of the points, but some of them may be useful.

1. Design is a profession. You have to learn it, just as you have to learn to be a doctor or an architect. The best way to learn is by doing it. Talent may account for up to 10% to 15% of your success; the rest is simply hard work. Experience will come with time. You don't “learn” experience, but you can always ask for advice from an experienced person.
2. For me, design is a 24/7 occupation. I think it is not possible to switch on and off the design process, particularly during the conceptual stage. The brain will work even when you are asleep. Sometimes developing the concept can become an obsession. Ideas can come very fast, or painfully slow. As my son Alex pointed out, there is always a risk in new design.
3. The designer/inventor always is convinced that his latest idea is the best. Friends and experts can help to weed out poor and impractical concepts.
4. Do your evaluation of performance and costs very carefully. Be honest with yourself. Keep searching for a solution in which you can believe 100%.
5. To be an efficient designer one should have a good knowledge of the fundamentals of engineering, material science, fabrication, and construction methods. Here I am asking for a lot, but the needed information is readily available. Sometimes it is efficient to consult with the people in the industry. I have learned from talking to pattern makers, foundry floor foremen, machinists, and welders. Using consultants may be less efficient and costly. It is better to talk to the machinist who hopes to make your part than to a consultant charging by the hour.
6. There is a large choice of materials. There are hundreds of metals and alloys, thousands of plastics and rubbers, and hundreds if not thousands of fibers and ceramics. There is also a very large supply of mechanical, hydraulic, pneumatic, and electrical devices/components available. Learn how to find them on the internet or in catalogs. You don't have to design a pressure regulator or an extreme-temperature sensor. Often you can get a sample.
7. Manufacturing is changing very fast. Laser cutting, water cutting, and bonding are a few of the new technologies available. Have your eyes and ears open and, if possible, establish a network of friendly suppliers who will be on the cutting edge of each technology. Before you ask a question, do your homework. It will save time.
8. A designer has to be familiar with the basic cost of materials and the cost of manufacturing, even if you design for NASA or the Navy.
9. My approach is to take a piece of paper and write down or sketch out the scope of what has to be designed. It is extremely important to define as closely as possible the objectives of the design. Then I suggest that you don't start by looking at what other designers have done in this field. Think on your own. You'll have a better chance of being innovative.
10. The best designs are done not by committees, but by individuals or small groups of individuals.
11. Conceptualize the basic design, draw it, analyze it and, if possible, prototype it and test it. Then, definitely simplify it.
12. It is very difficult to design something simple and it is very easy to design something complicated. It is amazing how many parts and components I usually manage to eliminate from my original design. If you work hard at the beginning, you save time and money.
13. Don't be afraid to change your design concept. Sometimes you will make several complete circles. Try to pick out the best.
14. When, and only when, you have your concept well developed and, if appropriate, prototyped and tested, study what others did to solve the same problem. You may win or lose, but you have a better chance of being innovative.
15. Don't over analyze. The computer is a tool, but not yet a source of new design. The internet is a priceless library, but you have to learn to use it in a time-efficient way. The internet may help, but it also may be a distraction and can steal your time.
16. Don't be afraid to think out of the box. How can you learn that? I would say simply by doing it most of the time.
17. Remember that function and quality are the most important. The “thing” has to work and work well. No compromise here.