As part of a design challenge, students learn how to use a rotation sensor (located inside the casing of a LEGO® MINDSTORMS ® NXT motor) to measure how far a robot moves with each rotation. Through experimentation and measurement with the sensor, student pairs determine the relationship between the number of rotations of the robot's wheels and the distance traveled by the robot. Then they use this ratio to program LEGO robots to move precise distances in a contest of accuracy. The robot that gets closest to the goal without touching the toy figures at the finish line is the winning programming design. Students learn how rotational sensors measure distance, how mathematics can be used for real-world purposes, and about potential sources of error due to gearing when using rotation sensor readings for distance calculations. They also become familiar with the engineering design process as they engage in its steps, from understanding the problem to multiple test/improve iterations to successful design.

Multi-scale systems (MuSS) consist of components from two or more length scales (nano, micro, meso, or macro-scales). In MuSS, the engineering modeling, design principles, and fabrication processes of the components are fundamentally different. The challenge is to make these components so they are conceptually and model-wise compatible with other-scale components with which they interface. This course covers the fundamental properties of scales, design theories, modeling methods and manufacturing issues which must be addressed in these systems. Examples of MuSS include precision instruments, nanomanipulators, fiber optics, micro/nano-photonics, nanorobotics, MEMS (piezoelectric driven manipulators and optics), X-Ray telescopes and carbon nano-tube assemblies. Students master the materials through problem sets and a project literature critique.

Student pairs experience the iterative engineering design process as they design, build, test and improve catching devices to prevent a "naked" egg from breaking when dropped from increasing heights. To support their design work, they learn about materials properties, energy types and conservation of energy. Acting as engineering teams, during the activity and competition they are responsible for design and construction planning within project constraints, including making engineering modifications for improvement. They carefully consider material choices to balance potentially competing requirements (such as impact-absorbing and low-cost) in the design of their prototypes. They also experience a real-world transfer of energy as the elevated egg's gravitational potential energy turns into kinetic energy as it falls and further dissipates into other forms upon impact. Pre- and post-activity assessments and a scoring rubric are provided. The activity scales up to district or regional egg drop competition scale. As an alternative to a ladder, detailed instructions are provided for creating a 10-foot-tall egg dropper rig.

Using their knowledge of the phases of matter, the scientific method, and polymers, student teams work as if they are chemical engineers to optimize the formula for slime. Hired by the fictional company, Slime Productions, students are challenged to modify the chemical composition of the basic formula for slime to maximize its "bounce factor."

Student groups work with manipulatives—pencils and trays—to maximize various quantities of a system. They work through three linear optimization problems, each with different constraints. After arriving at a solution, they construct mathematical arguments for why their solutions are the best ones before attempting to maximize a different quantity. To conclude, students think of real-world and engineering space optimization examples—a frequently encountered situation in which the limitation is the amount of space available. It is suggested that students conduct this activity before the associated lesson, Linear Programming, although either order is acceptable.

Using paper, paper clips and tape, student teams design flying/falling devices to stay in the air as long as possible and land as close as possible to a given target. Student teams use the steps of the engineering design process to guide them through the initial conception, evaluation, testing and re-design stages. The activity culminates with a classroom competition and scoring to evaluate how each team's design performed.

The difference between an architect and an engineer is sometimes confusing because their roles in building design can be similar. Students experience a bit of both professions by following a set of requirements and meeting given constraints as they create a model parking garage. They experience the engineering design process first-hand as they design, build and test their models. They draw a blueprint for their design, select the construction materials and budget their expenditures. They also test their structures for strength and find their maximum loads.

To gain a better understanding of the roles and functions of components of the human respiratory system and our need for clean air, students construct model lungs that include a diaphragm and chest cavity. They see how air moving in and out of the lungs coincides with diaphragm movement. Then student teams design and build a prototype face mask pollution filter. They use their model lungs to evaluate their prototypes to design requirements.

Students follow the steps of the engineering design process while learning more about assistive devices and biomedical engineering applied to basic structural engineering concepts. Their engineering challenge is to design, build and test small-scale portable wheelchair ramp prototypes for fictional clients. They identify suitable materials and demonstrate two methods of representing design solutions (scale drawings and simple models or classroom prototypes). Students test the ramp prototypes using a weighted bucket; successful prototypes meet all the student-generated design requirements, including support of a predetermined weight.

Students learn about material reuse by designing and building the strongest and tallest towers they can, using only recycled materials. They follow design constraints and build their towers to withstand earthquake and high wind simulations.

Students groups act as NASA/GM engineers challenged to design, build and test robotic hands, which are tactile feedback systems made from cloth gloves and force sensor circuits. Student groups construct force sensor circuits using electric components and FlexiForce sensors to which resistance changes based on the applied force. They conduct experiments to find the mathematical relationship between the force applied to the sensor and the output voltages of the circuit. They take several measurements force vs. resistance, force vs. voltage and use the data to find the best fit curve models for the sensor. Different weights applied to the sensor are used as a scalable force. Students use traditional methods and current technology (calculators) to plot the collected data and define the curve equations. Students test their gloves and use a line of best fit to determine the minimum force required to crack an egg held between the index finger and thumb. A PowerPoint(TM) file and many student handouts are included.

Students design and create sensory integration toys for young children with developmental disabilities an engineering challenge that combines the topics of biomedical engineering, engineering design and human senses. Students learn the steps of the engineering design process (EDP) and how to use it for problem solving. After learning about the human sensory system, student teams apply the EDP to their sensory toy projects. They design and make plans within given project constraints, choose materials, fabricate prototypes, evaluate the prototypes, and give and receive peer feedback. Students experience the entire design-build-test-redesign process and conclude with a class presentation in which they summarize their experiences with the EDP steps and their sensory toy project development.

Students learn how engineering design is applied to solve healthcare problems by using an engineering tool called simulation. While engineering design is commonly used to study and design everything from bridges, factories, airports to space shuttles, the use of engineering design to study healthcare administration and delivery is a relatively new concept.

Student pairs design, build and test model vehicles capable of rolling down a ramp and then coasting freely as far as possible. The challenge is to make the vehicles entirely out of dry pasta using only adhesive (such as hot glue) to hold the components together. Creativity is encouraged and different types of pasta are provided to support different functions such as round pasta for wheels and sheet pasta for the chassis. Students become familiar with the concepts of gravitational potential energy, kinetic energy and rolling resistance. Teams follow the steps of the engineering design process as they design, test and redesign their small-sized vehicles, working within the project's material constraints. The winner of the competitive final event is the pasta car that travels the longest distance beyond the bottom of the ramp.

Students are introduced to static equilibrium by learning how forces and torques are balanced in a well-designed engineering structure. A tower crane is presented as a simplified two-dimensional case. Using Popsicle sticks and hot glue, student teams design, build and test a simple tower crane model according to these principles, ending with a team competition.

Students are challenged to design, build and test small-scale launchers while they learn and follow the steps of the engineering design process. For the challenge, the "slingers" must be able to aim and launch Ping-Pong balls 20 feet into a goal using ordinary building materials such as tape, string, plastic spoons, film canisters, plastic cups, rubber bands and paper clips. Students first learn about defining the problem and why each step of the process is important. Teams develop solutions and determine which is the best based on design requirements. After making drawings, constructing and testing prototypes, they evaluate the results and make recommendations for potential second-generation prototypes.

This course studies what makes a good design and how one develops a good design. Students consider how the design of engineered systems (such as hardware, software, materials, and manufacturing systems) differ from the "design" of natural systems such as biological systems; discuss complexity and how one makes use of complexity theory to improve design; and discover how one uses axiomatic design theory (AD theory) in design of many different kinds of engineered systems. Questions are analyzed using Axiomatic Design Theory and Complexity Theory. Case studies are presented including the design of machines, tribological systems, materials, manufacturing systems, and recent inventions. Implications of AD and complexity theories on biological systems discussed.

Students learn about glaucoma its causes, how it affects individuals and how biomedical engineers can identify factors that trigger or cause this eye disease, specifically the increase of pressure in the eye. Students also learn how RFID technologies transfer energy through waves and how engineers apply their scientific understanding of waves, energy and sensors to develop devices that measure the pressure in the eyes of people with glaucoma. Students conclude by sketching their own designs for a pressure-measuring eye device, preparing them to conduct the associated activity in which they revise, prototype and evaluate their device designs made tangible with a 3D printer.

The Tippy Tap hand-washing station is an inexpensive and effective device used extensively in the developing world. One shortcoming of the homemade device is that it must be manually refilled with water and therefore is of limited use in high-traffic areas. In this activity, student teams design, prototype and test piping systems to transport water from a storage tank to an existing Tippy Tap hand-washing station, thereby creating a more efficient hand-washing station. Through this example service-learning engineering project, students learn basic fluid dynamic principles that are needed for creating efficient piping systems.

Students apply their knowledge about mountains and rocks to transportation engineering, with the task of developing a model mountain tunnel that simulates the principles behind real-life engineering design. Student teams design and create model tunnels through a clay mountain, working within design constraints and testing for success; the tunnels must meet specific design requirements and withstand a certain load.