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Mechanical Design Practice

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CMM Measurement Basics: How Coordinate Measuring Machines Verify Your Tolerances

For most of my career as a mechanical designer, the coordinate measuring machine was somewhere on the other side of a gl...
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Production Line Balancing for Machine Designers: Designing Equipment That Matches Takt Time

Early in my time as a contract engineer stationed inside a manufacturer's plant, I designed a welding cell that I was ge...
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Poka-Yoke in Design: Building Mistake-Proofing Directly Into Your Parts

Early in my career I designed a bracket that could be installed backward. It was symmetric enough that an assembler in a...
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Jig and Fixture Design Fundamentals: Locating, Clamping, and Repeatability

I still remember the first fixture I designed on my own, early in my career as a contract designer stationed at a manufa...
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First Article Inspection: What Designers Need to Prepare Before Mass Production

The first time I sat through a first article inspection review as a junior designer, I mostly watched the quality team a...
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PPAP Basics for Mechanical Engineers: Supplier Qualification Documentation Explained

The first time a purchasing manager asked me to "get the PPAP package ready" for a new stamped bracket, I nodded like I ...
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Composite Materials in Mechanical Design: Where Carbon Fiber Beats Metal

I spent the first decade of my career almost entirely in steel and aluminum, and I'll admit I was skeptical the first ti...
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Statistical Process Control for Design Engineers: Reading Cp/Cpk to Judge Process Capability

For most of my early years as a mechanical designer, I treated process capability indices like Cp and Cpk as something q...
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Powder Metallurgy Parts: Design Rules and When Sintered Components Make Sense

I still remember the first time a purchasing manager asked me to convert a machined steel bracket to powder metallurgy "...
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Metal 3D Printing for Production Parts: Mechanical Properties You Can Actually Rely On

Every few months for the past several years, someone at whatever manufacturer I'm stationed at asks whether we can just ...