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Mechanical Design Practice

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Design for Six Sigma (DFSS) for Mechanical Engineers: Applying Six Sigma Tools Before Production

Most mechanical engineers first encounter Six Sigma as a set of quality tools applied after a product is already in prod...
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Electrical Enclosure Design for Mechanical Engineers: Sizing, Cooling, and Cable Entry

Electrical enclosure design tends to land on a mechanical engineer's desk almost by default, treated as a leftover box t...
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Design for Noise Reduction: Practical Acoustic Strategies for Machine Designers

Noise is the design requirement that gets written into the spec sheet as an afterthought and then becomes the reason a m...
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Lubrication System Design: Grease vs Oil, Delivery Methods, and Maintenance Intervals

Lubrication is one of those design decisions that gets made in five minutes during a component selection meeting and the...
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CFD Basics for Mechanical Engineers: When You Need Fluid Simulation and When You Don’t

Somewhere in my second decade as a mechanical designer, I went through a phase where I wanted to run CFD on nearly every...
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FEA Fundamentals: Mesh, Boundary Conditions, and Interpreting Results Correctly

I have been running finite element analysis as part of my day job for most of the twenty years I have spent as a contrac...
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Digital Twin Basics for Machine Designers: Connecting CAD Models to Real Equipment Data

I used to think "digital twin" was one of those terms that consultants invented to make an existing practice sound new, ...
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IoT Sensors in Machine Design: Adding Condition Monitoring Without Overengineering

Somewhere around my twelfth year designing production machinery, I noticed a pattern in how condition monitoring got spe...
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Topology Optimization in Mechanical Design: Letting Software Find the Lightest Shape

The first time I ran a topology optimization job on a real production part, I stared at the resulting mesh for a solid t...
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Generative Design Tools: What They Actually Produce and How to Use the Output

Generative design got pitched to me, back when I first tried it on a real job, as a tool that would "design the part for...