Lab Manual Page

Objective

By the end of the workshop, students will be able to:

1. Define a prototype and the design thinking process
2. Identify and become familiar with the rapid prototyping techniques
3. Apply the design thinking process to ideate prototypes of engineering solutions

Background Information

The design thinking process is a framework that allows engineers to take a human-centered, iterative approach to problem solving (d.school, 2010). The process comprises five stages, where designers empathize with their audience, define their audience’s needs and the problem to solve, ideate or brainstorm solutions to the problem, prototype or draft a solution, and finally test their solution for feedback (Figure 1).

Figure 1. The design thinking process, as outlined by the Stanford d. school. The process requires designers to empathize with users, define user needs, ideate a solution, prototype the solution, and test the solution.

All engineering solutions begin with prototypes that help designers to explore, test, and analyze the solution that they are developing. While the exact definition of a prototype depends on its purpose, a prototype is generally a model that provides insight into the future of a product or object (Jensen et al. 2016).  Good prototypes are cost-effective, perform well, and use the fewest amount of resources needed while maintaining safety and efficacy of the final product. A prototype does not have to immediately showcase all of the finished functionalities of a product; it may be designed to highlight its essential features. Consider, for example, the four prototypes of a padlock shown in Figure 2 (Jensen et. al. 2018). While each prototype highlights the basic function of a padlock, the realism of the prototype varies. In this example, the realism of the prototype changes with material choice (cardboard, plywood, plastic, and metal).

Figure 2. Four prototypes of a padlock made of different material (from left to right: cardboard, plywood, plastic, and metal).

Prototypes can be classified along two dimensions that relate to its nature (Figure 3). In the first dimension, the prototype can be analytical or simulated, for example a circuit simulation or digital renderings of a design; or it can be physical, built from components that can be interacted with in real life, such as a wired breadboard. In the second dimension, the prototype can be focused, exhibiting one of the functionalities of the finished product in a very thorough manner, such as a breadboard that powers a single LED; or it can be comprehensive, showcasing many functions of the product, such as a circuit with interdependent components (Ulrich et al., 2020).

Figure 3. Prototypes can be categorized by types along two dimensions – physical versus analytical, and focused versus comprehensive.

In EG-UY 1004, the semester-long design project will require teams to assemble prototypes that are physical and comprehensive.

The appropriate method for prototyping depends on the nature of the prototype. Engineers consider the techniques that minimize the amount of resources – such as labor, time, and money – needed to effectively communicate their design. Rapid prototyping techniques allow designers to quickly transform analytical prototypes – such as a digital rendering or circuit diagram – into physical prototypes through a number of methods. Common rapid prototyping methods include laser cutting, 3D printing, and CNC milling (eFunda, 2025). Figure 4 describes examples of prototypes manufactured from each method. In laser cutting, a high power laser cuts or engraves a material such as cardboard, wood, or acrylic. In 3D printing, a machine builds an object layer by layer from a digital design. The printer filament can be made from plastic, resin, or metal. In CNC milling, a machine selectively removes material to create an object. CNC milling can be used with a broad range of materials, including plastic, metal, and wood, where precision is necessary for the design.

Figure 4. Common rapid prototyping tools (a laser cutter, 3D printer, and CNC mill) and examples of projects fabricated using those tools.

Workshop Activity

This workshop provides practice ideating engineering solutions to real-world problems. TAs will provide teams with a prompt, a list of available resources, and design considerations.

Materials 

• A writing utensil
• Sheet of paper

Procedure

1. Sit in teams of 3-4 students, as instructed by the TA.
2. The TA will spin a virtual wheel, randomly selecting three components that must be incorporated into a prototype. The prototype must address a problem defined by the TA. The design can include components additional to the 3 provided by the TA. Appendix A contains the list of components that will be present on the virtual wheel. The full list of materials available in EG-UY 1004 here.
3. For 10 minutes, ideate among team members. Write down answers to the following questions:

• Describe what a focused, analytical prototype of the product would be.
• Describe what a comprehensive, physical version of the prototype would be.
• Define the function of each of the sensors in the prototype, and how the sensors work together.
• Propose a method (for example, 3D printing) to fabricate the prototype.

4. Present the idea to the class. Each team will have 2 minutes to present.
5. The TA will provide feedback to each team.

Assignment

Prototyping is the foundation of the semester-long design project. The first team task of the semester-long design project is to ideate project proposals with a TA.

To prepare for the ideation session, read the lab manual pages related to the semester-long design project and General Engineering Design Challenge. Reflect on each of the project tracks. Brainstorm five project ideas related to any of the tracks. Document your ideas using this template.

To submit this assignment, upload the document as a .docx file to the EG website. The deadline for submission is 11:59pm the night before Skills Workshop 2.

Additional Resources

• Skills Workshop 1 Slides
• NYU MakerSpace Website
• Introduction to the MakerSpace

References

d. School. 2010. “An Introduction to Design Thinking Process Guide.” Accessed 30 July 2025 from https://web.stanford.edu/~mshanks/MichaelShanks/files/509554.pdf

Jensen et al. 2016. “Prototypes in engineering design: Definitions and strategies.” Accessed 22 December 2023 from https://www.designsociety.org/publication/38892/PROTOTYPES+IN+ENGINEERING+DESIGN%3A+DEFINITIONS+AND+STRATEGIES/

Ulrich, Karl T, et al. 2020. Product Design and Development. New York, Ny, Mcgraw-Hill Education.

Appendix A. Workshop Activity Components

Table 1. Skills Workshop 1 Activity Components