Through Internet research, patent research, standards and codes research, user interviews (if possible) and other techniques (idea web, reverse engineering), students further develop the context for their design challenge. In subsequent activities, the design teams use this body of knowledge about the problem to generate product design ideas. (Note: Conduct this activity in the context of a design project that students are working on, which could be a challenge determined by the teacher, brainstormed with the class, or the example project challenge provided [to design a prosthetic arm that can perform a mechanical function]. This activity is Step 2 in a series of six that guide students through the engineering design loop.)

Brainstorming is a team creativity activity that helps generate a large number of potential solutions to a problem. In this activity, students participate in a group brainstorming activity to generate possible solutions to their engineering design challenge. Students learn brainstorming guidelines and practice within their teams to create a poster of ideas. The posters are used in a large group critiquing activity that ultimately helps student teams create a design project outline. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 3 in a series of six that guide students through the engineering design loop.)

Students learn about the manufacturing phase of the engineering design process. They start by building prototypes, which is a special type of model used to test new design ideas. Students gain experience using a variety of simple building materials, such as foam core board, balsa wood, cardstock and hot glue. They present their prototypes to the class for user testing and create prototype iterations based on feedback. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 5 in a series of six that guide students through the engineering design loop.)

As students learn more about the manufacturing process, they use the final prototypes created in the previous activity to evaluate, design and manufacture final products. Teams work with more advanced materials and tools, such as plywood, Plexiglas, metals, epoxies, welding materials and machining tools. (Note: Conduct this activity in the context of a design project that students are working on; this activity is Step 6 in a series of six that guide students through the engineering design loop.)

Engineer and cartoonist Rube Goldberg is famous for his crazy machines that accomplish everyday tasks in overly complicated ways. Students use their new understanding of types of simple machines to design and build their own Rube Goldberg machines that perform simple tasks in no less than 10 steps.

Students are given a biomedical engineering challenge, which they solve while following the steps of the engineering design process. In a design lab environment, student groups design, create and test prototype devices that help people using crutches carry things, such as books and school supplies. The assistive devices must meet a list of constraints, including a device weight limit and minimum load capacity. Students use various hand and power tools to fabricate the devices. They test the practicality of their designs by loading them with objects and then using the modified crutches in the school hallways and classrooms.

Student teams use their knowledge about ancient Egypt to design playgrounds for Egyptian children. This involves brainstorming ideas on paper, building models with LEGO® bricks or other materials, and explaining their ideas to the class in five-minute presentations.

Student teams act as engineers and brainstorm, design, create and test their ideas for packaging to protect a raw egg shipped in a 9 x 12-in envelope. They follow the steps of the engineering design process and aim for a successful solution with no breakage, low weight, minimal materials and recyled/reused materials. Students come to understand the multi-faceted engineering considerations associated with the packaging of items to preserve, market and safely transport goods.

Student teams create laparoscopic surgical robots designed to reduce the invasiveness of diagnosing endometriosis and investigate how the disease forms and spreads. Using a synthetic abdominal cavity simulator, students test and iterate their remotely controlled, camera-toting prototype devices, which must fit through small incisions, inspect the organs and tissue for disease, obtain biopsies, and monitor via ongoing wireless image-taking. Note: This activity is the core design project for a semester-long, three-credit high school engineering course. Refer to the associated curricular unit for preparatory lessons and activities.

Testing is critical to any design, whether the creation of new software or a bridge across a wide river. Despite risking the quality of the design, the testing stage is often hurried in order to get products to market. In this lesson, students focus on the testing phase of the software/systems design process. They start by exploring existing examples of program testing using the CodingBat website, which contains a series of problems and challenges that students solve using the Java programming language. Working in teams, students practice writing test cases for other groups' code, and then write test cases for a program before writing the program itself.

Following the steps of the iterative engineering design process, student teams use what they learned in the previous lessons and activity in this unit to research and choose materials for their model heart valves and test those materials to compare their properties to known properties of real heart valve tissues. Once testing is complete, they choose final materials and design and construct prototype valve models, then test them and evaluate their data. Based on their evaluations, students consider how they might redesign their models for improvement and then change some aspect of their models and retest aiming to design optimal heart valve models as solutions to the unit's overarching design challenge. They conclude by presenting for client review, in both verbal and written portfolio/report formats, summaries and descriptions of their final products with supporting data.

Students' understanding of how robotic ultrasonic sensors work is reinforced in a design challenge involving LEGO MINDSTORMS(TM) NXT robots and ultrasonic sensors. Student groups program their robots to move freely without bumping into obstacles (toy LEGO people). They practice and learn programming skills and logic design in parallel. They see how robots take input from ultrasonic sensors and use it to make decisions to move, resulting in behavior similar to the human sense of sight but through the use of sound sensors, more like echolocation. Students design-test-redesign-retest to achieve successful programs. A PowerPoint® presentation and pre/post quizzes are provided.

Student groups are provided with a generic car base on which to design a device/enclosure to protect an egg on or in the car as it rolls down a ramp at increasing slopes. During this in-depth physics/science/technology activity, student teams design, build and test their creations to meet the design challenge, and are expected to perform basic mathematical calculations using collected data, including a summative cost to benefit ratio.

Students further their understanding of the engineering design process (EDP) while applying researched information on transportation technology, materials science and bioengineering. Students are given a fictional client statement (engineering challenge) and directed to follow the steps of the EDP to design prototype patient safety systems for small-size model ambulances. While following the steps of the EDP, students identify suitable materials and demonstrate two methods of representing solutions to the design challenge (scale drawings and small-scale prototypes). A successful patient safety system meets all of the project's functions and constraints, including the model patient (a raw egg) "surviving" a front-end collision test with a 1:8 ramp pitch.

Students learn about the engineering design process and how it is used to engineer products for everyday use. Students individually brainstorm solutions for sorting coins and draw at least two design ideas. They work in small groups to combine ideas and build a coin sorter using common construction materials such as cardboard, tape, straws and fabric. Students test their coin sorters, make revisions and suggest ways to improve their designs. By designing, building, testing and improving coin sorters, students come to understand how the engineering design process is used to engineer products that benefit society.

Students learn about applied forces as they create pop-up-books the art of paper engineering. They also learn the basic steps of the engineering design process.

Students follow the steps of the engineering design process (EDP) while learning about assistive devices and biomedical engineering. They first go through a design-build-test activity to learn the steps of the cyclical engineering design process. Then, during the three main activities (7 x 55 minutes each) student teams are given a fictional client statement and follow the EDP steps to design products an off-road wheelchair, a portable wheelchair ramp, and an automatic floor sweeper computer program. Students brainstorm ideas, identify suitable materials and demonstrate different methods of representing solutions to their design problems scale drawings or programming descriptions, and simple models or classroom prototypes.

Students learn about the process of reverse engineering and how this technique is used to improve upon technology. Students analyze push-toys and draw diagrams of the predicted mechanisms inside the toys. Then, they disassemble the toys and draw the actual inner mechanisms. By understanding how the push-toys function, students make suggestions for improvement, such as cost effectiveness, improved functionality, ecological friendliness and any additional functionality they determine is an improvement.

In this service-learning engineering project, students follow the steps of the engineering design process to design an assistive eating device for a client. More specifically, they design a prototype device to help a young girl who has a medical condition that restricts the motion of her joints. Her wish is to eat her favorite food, pizza, without getting her nose wet. Students learn about arthrogryposis and how it affects the human body as they act as engineers to find a solution to this open-ended design challenge and build a working prototype. This project works even better if you arrange for a client in your own community.

Students use the engineering design process to solve a real-world problem shoe engineering! Working in small teams, they design, build and test a pair of wearable platform or high-heeled shoes, taking into consideration the stress and strain forces that it will encounter from the shoe wearer. They conclude the activity with a "walk-off" to test the shoe designs and discuss the design process.