30+ Design & Development Engineer Interview Questions and Answers

I would analyze the reasons for failure and work on improving the product or developing a new one.

• Conduct a thorough analysis of the reasons for failure

• Identify areas of improvement and work on them

• Develop a new product based on customer feedback and market research

• Offer refunds or compensation to customers if necessary

• Collaborate with the team to learn from the failure and prevent it from happening again

Design and scope involve stress-strain diagrams, surface finish, fits and tolerances, and kg force.

• Design and scope refer to the planning and execution of a project.

• Stress-strain diagrams show the relationship between stress and strain in a material.

• Surface finish refers to the texture of a material's surface, while roughness is the measure of irregularities on the surface.

• Kg force is a unit of force in the metric system.

• Fits and tolerances are used to ensure that parts fit t...read more

The density of PP (Polypropylene) is approximately 0.9 grams per cubic centimeter.

• PP has a relatively low density compared to other plastics.

• The density of PP can vary slightly depending on the specific grade and manufacturing process.

• For example, a common grade of PP has a density of around 0.9 g/cm³.

• The density of PP is lower than that of materials like PVC (polyvinyl chloride) or HDPE (high-density polyethylene).

Considerations for designing sheet metal parts

• Material selection based on strength, corrosion resistance, and formability

• Determining appropriate sheet metal thickness for structural integrity

• Designing for manufacturability, including proper bend radii and tolerances

• Considering the impact of welding or joining methods on the design

• Accounting for potential deformation during fabrication processes

• Optimizing part geometry for cost-effective production

• Ensuring proper nesting and e...read more

Design is the process of creating a plan or blueprint for a product or system.

• Design involves identifying the problem and finding a solution

• It requires creativity, critical thinking, and attention to detail

• Design should consider user needs, functionality, and aesthetics

• Examples of design include product design, graphic design, and architectural design

Designing products for molds involves considering the mold material, part geometry, and production volume.

• Determine the mold material based on the product material and production volume

• Consider part geometry and draft angles to ensure easy release from the mold

• Design for uniform wall thickness to prevent warping and sink marks

• Add fillets and radii to reduce stress concentrations and improve moldability

• Use simulation software to optimize mold design and identify potential issu...read more

My goal is to continuously learn and grow both personally and professionally.

• Continuously improve my skills and knowledge

• Take on challenging projects to push myself

• Build strong relationships with colleagues and mentors

• Contribute to the success of the company

• Maintain a healthy work-life balance

The density of ABS (Acrylonitrile Butadiene Styrene) is typically around 1.04 g/cm³.

• ABS is a common thermoplastic polymer used in various industries.

• The density of ABS can vary slightly depending on the specific formulation and additives.

• For example, ABS with higher levels of butadiene tends to have a lower density.

• The density of ABS is important to consider in applications where weight and volume are factors, such as in automotive parts or consumer products.

Strength can be maintained by optimizing the design, using high-strength materials, and reducing stress concentrations.

• Optimize the design to distribute loads evenly

• Use high-strength materials such as carbon fiber or titanium

• Reduce stress concentrations by using fillets or rounded corners

• Perform finite element analysis to identify areas of high stress

• Consider the manufacturing process and its impact on material properties

Edm stands for Electrical Discharge Machining, a process of shaping hard metals using electrical sparks.

• Edm uses electrical sparks to erode metal and create a desired shape

• It is commonly used in the manufacturing of aerospace and medical components

• Edm can be performed using wire or sinker machines

• The process is highly precise and can create complex shapes with tight tolerances

AutoCAD is a software used for creating, editing, and viewing 2D and 3D designs and drawings.

• AutoCAD is used for drafting and designing architectural, mechanical, electrical, and civil engineering projects.

• It allows precise and accurate creation of technical drawings, blueprints, and models.

• AutoCAD enables collaboration and sharing of designs among team members.

• It provides tools for dimensioning, annotation, and documentation of designs.

• AutoCAD can be used for creating 3D mod...read more

DFMEA is a design failure mode and effects analysis, APQP is advanced product quality planning, and PPAP is production part approval process.

• DFMEA is a systematic approach to identifying and preventing design failures.

• APQP is a structured process for developing new products and ensuring quality throughout the product lifecycle.

• PPAP is a set of procedures used to ensure that parts meet customer requirements and are ready for production.

• All three are commonly used in the automo...read more

The rule of 5s is a lean manufacturing principle that aims to reduce waste and improve efficiency.

• 5s stands for Sort, Set in Order, Shine, Standardize, and Sustain

• It involves organizing the workplace, eliminating unnecessary items, and maintaining cleanliness

• Examples include labeling tools and equipment, creating designated storage areas, and implementing regular cleaning schedules

The 3 2 1 principle is a rule of thumb for designing parts for manufacturing.

• It involves designing parts with no more than 3 major features, 2 intermediate features, and 1 minor feature.

• This helps simplify the manufacturing process and reduce costs.

• For example, a simple bracket may have 3 major features (mounting holes, bend, and flange), 2 intermediate features (rounded corners and chamfers), and 1 minor feature (a logo stamp).

Fundamentals of design include functionality, aesthetics, usability, and sustainability.

• Functionality: design should serve a purpose and meet user needs

• Aesthetics: design should be visually appealing and communicate a message

• Usability: design should be easy to use and understand

• Sustainability: design should consider environmental impact and resource usage

Vernier caliper is a precise measuring instrument used to measure dimensions accurately.

• Vernier caliper is used to measure the internal and external dimensions of an object.

• It consists of a main scale and a sliding vernier scale for more accurate readings.

• The main scale typically measures in millimeters, while the vernier scale allows for measurements in fractions of a millimeter.

• To use a vernier caliper, close the jaws around the object to be measured and read the measuremen...read more

The average distance between the sun and Earth is about 93 million miles.

• The distance between the sun and Earth is constantly changing due to the elliptical orbit of Earth around the sun.

• The average distance is known as an astronomical unit (AU) and is approximately 93 million miles or 150 million kilometers.

• This distance can vary from about 91.4 million miles (147.1 million kilometers) at the closest point (perihelion) to about 94.5 million miles (152.1 million kilometers) a...read more

CNC stands for Computer Numerical Control. VMC is a type of CNC machine used for milling operations.

• CNC machines are automated tools that use pre-programmed software to control their movements

• CNC machines can perform a wide range of operations including cutting, drilling, and milling

• VMC stands for Vertical Machining Center and is a type of CNC machine used for milling operations

• VMC machines have a vertical spindle axis, which allows for greater precision and accuracy in milli...read more

In India, the most commonly used angle method is the 'Angle of Repose' in various engineering applications.

• The Angle of Repose is the steepest angle at which a sloped surface formed of a particular material is stable.

• It is crucial in civil engineering for designing slopes, embankments, and retaining walls.

• For example, in the construction of a landfill, understanding the angle of repose helps in determining the stability of the waste pile.

• In mining, it helps in assessing the s...read more

To overcome a problem, it is important to analyze the root cause, brainstorm solutions, and implement the most effective one.

• Identify the root cause of the problem

• Brainstorm potential solutions

• Evaluate and select the most effective solution

• Implement the chosen solution

• Monitor and evaluate the results

• Iterate and make improvements if necessary

There are 5 types of fire: Class A, Class B, Class C, Class D, and Class K.

• Class A fires involve ordinary combustibles like wood, paper, and cloth.

• Class B fires involve flammable liquids and gases.

• Class C fires involve electrical equipment.

• Class D fires involve combustible metals.

• Class K fires involve cooking oils and fats.

• Each type of fire requires a specific type of extinguisher.

• It's important to know the type of fire before attempting to extinguish it.

Quantum mechanics is a branch of physics that deals with the behavior of particles at the smallest scales.

• Quantum mechanics describes the behavior of particles such as electrons and photons.

• It involves principles such as superposition, entanglement, and uncertainty.

• Quantum mechanics is essential for understanding phenomena like quantum tunneling and quantum computing.

Program to find and remove duplicate strings in an array

• Create an empty hash table

• Iterate through the array and add each string to the hash table

• If a string already exists in the hash table, remove it from the array

AutoCAD and SolidWorks are both computer-aided design (CAD) software, but they have different features and applications.

• AutoCAD is primarily used for 2D drafting and documentation, while SolidWorks is focused on 3D modeling and parametric design.

• AutoCAD is widely used in architecture, engineering, and construction industries, while SolidWorks is popular in mechanical and product design.

• SolidWorks offers advanced features like assembly modeling, simulation, and rendering, whic...read more

Designing a progressive tool involves creating a multi-stage die for efficient metal forming processes.

• Understand the material properties: Choose materials like steel or aluminum based on strength and ductility.

• Define the part geometry: Create detailed CAD models to visualize the final product.

• Determine the number of stages: Plan how many operations are needed to achieve the desired shape.

• Select the right tooling: Use punches, dies, and guides that suit the material and desig...read more

Design is the process of creating a plan or blueprint for the construction or creation of something.

• Design involves the creation of a plan or blueprint for a product, system, or structure.

• It includes considering the functionality, aesthetics, and usability of the design.

• Design can be applied to various fields such as industrial design, graphic design, and architectural design.

• Examples of design include designing a new car model, creating a logo for a company, or planning the ...read more

To make a 2D design, you can use software like AutoCAD or Adobe Illustrator.

• Choose a software suitable for 2D design, such as AutoCAD or Adobe Illustrator

• Start by creating a new document with the desired dimensions

• Use tools like lines, shapes, and curves to draw the design

• Add colors, textures, and other visual elements to enhance the design

• Save the design in a suitable file format, such as .dwg or .ai

Find the second largest string in an array of strings.

• Iterate through the array and keep track of the largest and second largest strings.

• Compare each string with the current largest and second largest strings.

• Return the second largest string at the end.